Assembly Complete for NASA’s First Orion Crew Module Blasting off Dec. 2014

NASA’s first completed Orion crew module sits atop its service module at the Neil Armstrong Operations and Checkout Facility at Kennedy Space Center in Florida in early September 2014. The crew and service module will be transferred soon to another facility for fueling. Credit: NASA/Rad Sinyak

This past weekend technicians completed assembly of NASA’s first Orion crew module at the agency’s Neil Armstrong Operations and Checkout (O & C) Facility at the Kennedy Space Center (KSC) in Florida, signifying a major milestone in the vehicles transition from fabrication to full scale launch operations.

Orion is NASA’s next generation human rated vehicle and is scheduled to launch on its maiden uncrewed mission dubbed Exploration Flight Test-1 (EFT-1) in December 2014. It replaces the now retired space shuttle orbiters.

The black Orion crew module (CM) sits stacked atop the white service module (SM) in the O & C high bay photos, shown above and below.

The black area is comprised of the thermal insulating back shell tiles. The back shell and heat shield protect the capsule from the scorching heat of re-entry into the Earth’s atmosphere at excruciating temperatures reaching over 4000 degrees Fahrenheit (2200 C) – detailed in my story here.

Technicians and engineers from prime contractor Lockheed Martin subsequently covered the crew module with protective foil. The CM/SM stack was then lifted and moved for the installation of the Orion-to-stage adapter ring that will mate them to the booster rocket.

Lifting and stacking NASA’s first completed Orion crew and service modules at the Neil Armstrong Operations and Checkout Facility at Kennedy Space Center in Florida in early September 2014.   Credit: NASA/Rad Sinyak
Lifting and stacking NASA’s first completed Orion crew and service modules at the Neil Armstrong Operations and Checkout Facility at Kennedy Space Center in Florida in early September 2014. Credit: NASA/Rad Sinyak

At the conclusion of the EFT-1 flight, the detached Orion capsule plunges back and hits the Earth’s atmosphere at 20,000 MPH (32,000 kilometers per hour).

“That’s about 80% of the reentry speed experienced by the Apollo capsule after returning from the Apollo moon landing missions,” Scott Wilson, NASA’s Orion Manager of Production Operations at KSC, told me during an interview at KSC.

The next step in Orion’s multi stage journey to the launch pad follows later this week with transport of the CM/SM stack to another KSC facility named the Payload Hazardous Servicing Facility (PHFS) for fueling, before moving again for the installation of the launch abort system (LAS) in yet another KSC facility.

Stacking NASA’s first completed Orion crew and service modules at the Neil Armstrong Operations and Checkout Facility at Kennedy Space Center in Florida in early September 2014.   Credit: NASA/Rad Sinyak
Stacking NASA’s first completed Orion crew and service modules at the Neil Armstrong Operations and Checkout Facility at Kennedy Space Center in Florida in early September 2014. Credit: NASA/Rad Sinyak

The Orion EFT-1 test flight is slated to soar to space atop the mammoth, triple barreled United Launch Alliance (ULA) Delta IV Heavy rocket from Cape Canaveral, Florida, on Dec. 4, 2014 .

The state-of-the-art Orion spacecraft will carry America’s astronauts on voyages venturing farther into deep space than ever before – past the Moon to Asteroids, Mars and Beyond!

NASA’s first completed Orion crew and service modules being moved inside the High Bay at the Neil Armstrong Operations and Checkout Facility at Kennedy Space Center in Florida in early September 2014.   Credit: NASA/Rad Sinyak
NASA’s first completed Orion crew and service modules being moved inside the High Bay at the Neil Armstrong Operations and Checkout Facility at Kennedy Space Center in Florida in early September 2014. Credit: NASA/Rad Sinyak

NASA is simultaneously developing a monster heavy lift rocket known as the Space Launch System or SLS, that will eventually launch Orion on its deep space missions.

The maiden SLS/Orion launch on the Exploration Mission-1 (EM-1) unmanned test flight is now scheduled for no later than November 2018 – read my story here.

SLS will be the world’s most powerful rocket ever built.

The two-orbit, four and a half hour EFT-1 flight will lift the Orion spacecraft and its attached second stage to an orbital altitude of 3,600 miles, about 15 times higher than the International Space Station (ISS) – and farther than any human spacecraft has journeyed in 40 years.

Orion service module assembly in the Operations and Checkout facility at Kennedy Space Center - now renamed in honor of Neil Armstrong.   Credit: Ken Kremer/kenkremer.com
Orion service module assembly in the Operations and Checkout facility at Kennedy Space Center – now renamed in honor of Neil Armstrong. Credit: Ken Kremer/kenkremer.com

The EFT-1 mission will test the systems critical for EM-1 and future human missions to deep space that follow.

The Orion EFT-1 capsule has come a long way over the past two years of assembly.

The bare bones, welded shell structure of the Orion crew cabin arrived at KSC in Florida from NASA’s Michoud facility in New Orleans in June 2012 and was officially unveiled at a KSC welcoming ceremony on 2 July 2012, attended by this author.

“Everyone is very excited to be working on the Orion. We have a lot of work to do. It’s a marathon not a sprint to build and test the vehicle,” said Jules Schneider, Orion Project manager for Lockheed Martin at KSC, during an exclusive 2012 interview with Universe Today inside the Orion clean room at KSC.

Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) mock up stack inside the transfer aisle of the Vehicle Assembly Building (VAB) at the Kennedy Space Center (KSC) in Florida.  Service module at bottom.  Credit: Ken Kremer/kenkremer.com
Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) mock up stack inside the transfer aisle of the Vehicle Assembly Building (VAB) at the Kennedy Space Center (KSC) in Florida. Service module at bottom. Credit: Ken Kremer/kenkremer.com

Stay tuned here for Ken’s continuing Orion, SLS, Boeing, Sierra Nevada, Orbital Sciences, SpaceX, commercial space, Curiosity, Mars rover, MAVEN, MOM and more Earth and planetary science and human spaceflight news.

Ken Kremer

Orion crew module back shell tiles and panels inside the Neil Armstrong Operations and Checkout Building high bay at the Kennedy Space Center in Florida.   Credit: Ken Kremer - kenkremer.com
Orion crew module back shell tiles and panels inside the Neil Armstrong Operations and Checkout Building high bay at the Kennedy Space Center in Florida. Credit: Ken Kremer – kenkremer.com
Orion EFT-1 capsule under construction inside the Structural Assembly Jig at the Operations and Checkout Building (O & C) at the Kennedy Space Center (KSC); Jules Schneider, Orion Project Manager for Lockheed Martin and Ken Kremer, Universe Today.  Credit: Ken Kremer - kenkremer.com
Orion EFT-1 capsule under construction inside the Structural Assembly Jig at the Operations and Checkout Building (O & C) at the Kennedy Space Center (KSC); Jules Schneider, Orion Project Manager for Lockheed Martin and Ken Kremer, Universe Today. Credit: Ken Kremer – kenkremer.com

Heat Protecting Back Shell Tiles Installed on NASA’s Orion EFT-1 Spacecraft Set for Dec. 2014 Launch

Inside the Operations and Checkout Building high bay at NASA's Kennedy Space Center in Florida, technicians dressed in clean-room suits install a back shell tile panel onto the Orion crew module. Credit: NASA/Dimitri Gerondidakis

Fabrication of the pathfinding version of NASA’s Orion crew capsule slated for its inaugural unmanned test flight in December is entering its final stages at the Kennedy Space Center (KSC) launch site in Florida.

Engineers and technicians have completed the installation of Orion’s back shell panels which will protect the spacecraft and future astronauts from the searing heat of reentry and scorching temperatures exceeding 3,150 degrees Fahrenheit.

Orion is scheduled to launch on its maiden uncrewed mission dubbed Exploration Flight Test-1 (EFT-1) test flight in December 2014 atop the mammoth, triple barreled United Launch Alliance (ULA) Delta IV Heavy rocket from Cape Canaveral, Florida.

Inside the Operations and Checkout Building high bay at NASA's Kennedy Space Center in Florida, technicians dressed in clean-room suits have installed a back shell tile panel onto the Orion crew module and are checking the fit next to the middle back shell tile panel. Preparations are underway for Exploration Flight Test-1, or EFT-1. Credit: NASA/Dimitri Gerondidakis
Inside the Operations and Checkout Building high bay at NASA’s Kennedy Space Center in Florida, technicians dressed in clean-room suits have installed a back shell tile panel onto the Orion crew module and are checking the fit next to the middle back shell tile panel. Preparations are underway for Exploration Flight Test-1, or EFT-1. Credit: NASA/Dimitri Gerondidakis

The cone-shaped back shell actually has a rather familiar look since its comprised of 970 black thermal protection tiles – the same tiles which protected the belly of the space shuttles during three decades and 135 missions of returning from space.

However, Orion’s back shell tiles will experience temperatures far in excess of those from the shuttle era. Whereas the space shuttles traveled at 17,000 miles per hour, Orion will hit the Earth’s atmosphere at some 20,000 miles per hour on this first flight test.

The faster a spacecraft travels through Earth’s atmosphere, the more heat it generates. So even though the hottest the space shuttle tiles got was about 2,300 degrees Fahrenheit, the Orion back shell could get up to 3,150 degrees, despite being in a cooler area of the vehicle.

Engineers have also rigged Orion to conduct a special in flight test to see just how vulnerable the vehicle is to the onslaught of micrometeoroid orbital debris.

Two one-inch-wide holes have been drilled into tiles on Orion’s back shell to simulate micrometeoroid orbital debris damage.  Sensors on the vehicle will record how high temperatures climb inside the hole during Orion’s return through Earth’s atmosphere following its first flight in December.  Credit:  NASA
Two one-inch-wide holes have been drilled into tiles on Orion’s back shell to simulate micrometeoroid orbital debris damage. Sensors on the vehicle will record how high temperatures climb inside the hole during Orion’s return through Earth’s atmosphere following its first flight in December. Credit: NASA

Even tiny particles can cause immense and potentially fatal damage at high speed by punching a hole through the back shell tiles and possibly exposing the spacecrafts structure to temperatures high than normal.

“Below the tiles, the vehicle’s structure doesn’t often get hotter than about 300 degrees Fahrenheit, but if debris breeched the tile, the heat surrounding the vehicle during reentry could creep into the hole it created, possibly damaging the vehicle,” says NASA.

The team has run done numerous modeling studies on the effect of micrometeoroid hits. Now it’s time for a real world test.

Therefore engineers have purposely drilled a pair of skinny 1 inch wide holes into two 1.47 inches thick tiles to mimic damage from a micrometeoroid hit. The holes are 1.4 inches and 1 inch deep and are located on the opposite side of the back shell from Orion’s windows and reaction control system jets, according to NASA.

“We want to know how much of the hot gas gets into the bottom of those cavities,” said Joseph Olejniczak, manager of Orion aerosciences, in a NASA statement.

“We have models that estimate how hot it will get to make sure it’s safe to fly, but with the data we’ll gather from these tiles actually coming back through Earth’s atmosphere, we’ll make new models with higher accuracy.”

Orion crew module back shell tiles and panels inside the Neil Armstrong Operations and Checkout Building high bay at the Kennedy Space Center in Florida.   Credit: Ken Kremer - kenkremer.com
Orion crew module back shell tiles and panels inside the Neil Armstrong Operations and Checkout Building high bay at the Kennedy Space Center in Florida. Credit: Ken Kremer – kenkremer.com

The data gathered will help inform the team about the heat effects from potential damage and possible astronaut repair options in space.

Orion is NASA’s next generation human rated vehicle now under development to replace the now retired space shuttle.

The state-of-the-art spacecraft will carry America’s astronauts on voyages venturing farther into deep space than ever before – past the Moon to Asteroids, Mars and Beyond!

The two-orbit, four and a half hour EFT-1 flight will lift the Orion spacecraft and its attached second stage to an orbital altitude of 3,600 miles, about 15 times higher than the International Space Station (ISS) – and farther than any human spacecraft has journeyed in 40 years.

The EFT-1 mission will test the systems critical for future human missions to deep space.

Orion’s back shell attachment and final assembly is taking place in the newly renamed Neil Armstrong Operations and Checkout Building, by prime contractor Lockheed Martin.

Inside the Operations and Checkout Building high bay at the Kennedy Space Center, Fl, technicians on work platform monitor progress as crane lowers the middle back shell tile panel for installation on the Orion crew module.   Credit: NASA/Dimitri Gerondidakis
Inside the Operations and Checkout Building high bay at the Kennedy Space Center, Fl, technicians on work platform monitor progress as crane lowers the middle back shell tile panel for installation on the Orion crew module. Credit: NASA/Dimitri Gerondidakis

One of the primary goals of NASA’s eagerly anticipated Orion EFT-1 uncrewed test flight is to test the efficacy of the heat shield and back shell tiles in protecting the vehicle – and future human astronauts – from excruciating temperatures reaching over 4000 degrees Fahrenheit (2200 C) during scorching re-entry heating.

At the conclusion of the EFT-1 flight, the detached Orion capsule plunges back and re-enters the Earth’s atmosphere at 20,000 MPH (32,000 kilometers per hour).

“That’s about 80% of the reentry speed experienced by the Apollo capsule after returning from the Apollo moon landing missions,” Scott Wilson, NASA’s Orion Manager of Production Operations at KSC, told me during an interview at KSC.

A trio of parachutes will then unfurl to slow Orion down for a splashdown in the Pacific Ocean.

The Orion EFT-1 vehicle is due to roll out of the O & C in about two weeks and be moved to its fueling facility at KSC for the next step in launch processing.

Orion will eventually launch atop the SLS, NASA’s new mammoth heavy lift booster which the agency is now targeting for its maiden launch no later than November 2018 – detailed in my story here.

Stay tuned here for Ken’s continuing Orion, SLS, Boeing, Sierra Nevada, Orbital Sciences, SpaceX, commercial space, Curiosity, Mars rover, MAVEN, MOM and more Earth and planetary science and human spaceflight news.

Ken Kremer

US Heavy Lift Mars Rocket Passes Key Review and NASA Sets 2018 Maiden Launch Date

Looking to the future of space exploration, NASA and TopCoder have launched the "High Performance Fast Computing Challenge" to improve the performance of their Pleiades supercomputer. Credit: NASA/MSFC

Artist concept of NASA’s Space Launch System (SLS) 70-metric-ton configuration launching to space. SLS will be the most powerful rocket ever built for deep space missions, including to an asteroid and ultimately to Mars. Credit: NASA/MSFC
Story updated[/caption]

After a thorough review of cost and engineering issues, NASA managers formally approved the development of the agency’s mammoth heavy lift rocket – the Space Launch System or SLS – which will be the world’s most powerful rocket ever built and is intended to take astronauts farther beyond Earth into deep space than ever before possible – to Asteroids and Mars.

The maiden test launch of the SLS is targeted for November 2018 and will be configured in its initial 70-metric-ton (77-ton) version, top NASA officials announced at a briefing for reporters on Aug. 27.

On its first flight known as EM-1, the SLS will also loft an uncrewed Orion spacecraft on an approximately three week long test flight taking it beyond the Moon to a distant retrograde orbit, said William Gerstenmaier, associate administrator for the Human Explorations and Operations Mission Directorate at NASA Headquarters in Washington, at the briefing.

Previously NASA had been targeting Dec. 2017 for the inaugural launch from the Kennedy Space Center in Florida – a slip of nearly one year.

But the new Nov. 2018 target date is what resulted from the rigorous assessment of the technical, cost and scheduling issues.

This artist concept shows NASA’s Space Launch System, or SLS, rolling to a launch pad at Kennedy Space Center at night. SLS will be the most powerful rocket in history, and the flexible, evolvable design of this advanced, heavy-lift launch vehicle will meet a variety of crew and cargo mission needs.   Credit:  NASA/MSFC
This artist concept shows NASA’s Space Launch System, or SLS, rolling to a launch pad at Kennedy Space Center at night. SLS will be the most powerful rocket in history, and the flexible, evolvable design of this advanced, heavy-lift launch vehicle will meet a variety of crew and cargo mission needs. Credit: NASA/MSFC

The decision to move forward with the SLS comes after a wide ranging review of the technical risks, costs, schedules and timing known as Key Decision Point C (KDP-C), said Associate Administrator Robert Lightfoot, at the briefing. Lightfoot oversaw the review process.

“After rigorous review, we’re committing today to a funding level and readiness date that will keep us on track to sending humans to Mars in the 2030s – and we’re going to stand behind that commitment,” said Lightfoot. “Our nation is embarked on an ambitious space exploration program.”

“We are making excellent progress on SLS designed for missions beyond low Earth orbit,” Lightfoot said. “We owe it to the American taxpayers to get it right.”

He said that the development cost baseline for the 70-metric ton version of the SLS was $7.021 billion starting from February 2014 and continuing through the first launch set for no later than November 2018.

Lightfoot emphasized that NASA is also building an evolvable family of vehicles that will increase the lift to an unprecedented lift capability of 130 metric tons (143 tons), which will eventually enable the deep space human missions farther out than ever before into our solar system, leading one day to Mars.

“It’s also important to remember that we’re building a series of launch vehicles here, not just one,” Lightfoot said.

Blastoff of NASA’s Space Launch System (SLS) rocket and Orion crew vehicle from the Kennedy Space Center, Florida.   Credit: NASA/MSFC
Blastoff of NASA’s Space Launch System (SLS) rocket and Orion crew vehicle from the Kennedy Space Center, Florida. Credit: NASA/MSFC

Lightfoot and Gerstenmaier both indicated that NASA hopes to launch sooner, perhaps by early 2018.

“We will keep the teams working toward a more ambitious readiness date, but will be ready no later than November 2018,” said Lightfoot.

The next step is conduct the same type of formal KDP-C reviews for the Orion crew vehicle and Ground Systems Development and Operations programs.

The first piece of SLS flight hardware already built and to be tested in flight is the stage adapter that will fly on the maiden launch of Orion this December atop a ULA Delta IV Heavy booster during the EFT-1 mission.

The initial 70-metric-ton (77-ton) version of the SLS stands 322 feet tall and provides 8.4 million pounds of thrust. That’s already 10 percent more thrust at launch than the Saturn V rocket that launched NASA’s Apollo moon landing missions, including Apollo 11, and it can carry more than three times the payload of the now retired space shuttle orbiters.

The core stage towers over 212 feet (64.6 meters) tall with a diameter of 27.6 feet (8.4 m) and stores cryogenic liquid hydrogen and liquid oxygen. Boeing is the prime contractor for the SLS core stage.

The first stage propulsion is powered by four RS-25 space shuttle main engines and a pair of enhanced five segment solid rocket boosters (SRBs) also derived from the shuttles four segment boosters.

The pressure vessels for the Orion crew capsule, including EM-1 and EFT-1, are also being manufactured at MAF. And all of the External Tanks for the space shuttles were also fabricated at MAF.

The airframe structure for the first Dream Chaser astronaut taxi to low Earth orbit is likewise under construction at MAF as part of NASA’s commercial crew program.

The first crewed flight of the SLS is set for the second launch on the EM-2 mission around the 2020/2021 time frame, which may visit a captured near Earth asteroid.

Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.

Ken Kremer

Enter the Dragon: First Look Inside SpaceX’s New Crew Transporter to Orbit – Photos

First look inside SpaceX Dragon V2 next generation astronaut spacecraft unveiled by CEO Elon Musk on May 29, 2014. Credit: Robert Fisher/America Space

Would you ‘Enter the Dragon’?
First look inside SpaceX Dragon V2 next generation astronaut spacecraft unveiled by CEO Elon Musk on May 29, 2014. Credit: Robert Fisher/AmericaSpace[/caption]

Would you like to ‘Enter the Dragon’ for an up close look inside SpaceX’s new ‘V2’ crew transport ship to Earth orbit and the space station?

We’ve shown you lots of exterior shots of SpaceX’s next generation manned Dragon V2 spacecraft after Billionaire entrepreneur and SpaceX CEO Elon Musk pulled the curtain off to reveal his future plans for human spaceflight on May 29 during a live webcast from SpaceX HQ in Hawthorne, Calif.

And we’ve shown you the cool animation to see exactly ‘How it Works!’ from launch to landing.

Now we’ve compiled a stunning collection of imagery revealing what it’s like to actually stand within the gleaming walls of the futuristic Dragon spaceship from an astronauts perspective.

Check out the gallery of Dragon V2 imagery above and below.

Elon Musk seated inside Dragon V2 explaining consoles at unveiling on May 29, 2014. Credit: SpaceX
Elon Musk seated inside Dragon V2 explaining consoles at unveiling on May 29, 2014. Credit: SpaceX

Experience this exciting new chapter of American ‘Commercial Human Spaceflight’ coming to fruition.

NASA’s Commercial Crew Program (CCP) is a public private partnership between NASA and a trio of amazing American aerospace companies – SpaceX, Boeing amd Sierra Nevada – to create inexpensive but reliable new astronaut spaceships to the High Frontier.

And NASA’s unprecedented commercial crew program is so far ahead of any international competitors that I think they’ll soon be knocking at the door and regret not investing in a similar insightful manner.

The goal is to get American’s back in space on American rockets from American soil – rather than being totally dependent on Russian rocket technology and Soyuz capsules for astronaut rides to the International Space Station (ISS) and back.

Potential crew members check out the seats of the new SpaceX Dragon V2 next generation astronaut spacecraft. Credit:  Robert Fisher/America Space
Potential crew members check out the seats of the new SpaceX Dragon V2 next generation astronaut spacecraft. Credit: Robert Fisher/America Space

“We need to have our own capability to get our crews to space. Commercial crew is really, really, really important,” NASA Administrator Charles Bolden told me in an exclusive interview – here.

SpaceX CEO Elon Musk pulls open the hatch to ;Enter the Dragon’.    Credit:  Robert Fisher/America Space
SpaceX CEO Elon Musk pulls open the hatch to ‘Enter the Dragon’. Credit: Robert Fisher/America Space

Boeing and Sierra Nevada are competing with SpaceX to build the next generation spaceship to ferry astronauts to and from the ISS by 2017 using seed money from NASA’s CCP.

The Boeing CST-100 and Sierra Nevada Dream Chaser ‘space taxis’ are also vying for funding in the next round of contracts to be awarded by NASA around late summer 2014.

A look through the open hatch of the Dragon V2 reveals the layout and interior of the seven-crew capacity spacecraft. Credit: NASA/Dimitri Gerondidakis
A look through the open hatch of the Dragon V2 reveals the layout and interior of the seven-crew capacity spacecraft. Credit: NASA/Dimitri Gerondidakis

Stay tuned here for Ken’s continuing SpaceX, Boeing, Sierra Nevada, Orbital Sciences, commercial space, Orion, Mars rover, MAVEN, MOM and more planetary and human spaceflight news.

Ken Kremer

The Dragon V2 spacecraft's seating arrangement with the control panel swung up to allow crewmembers to get into their seats. Once the crew is in place, the control panel swings down and locks in launch position. Credit: NASA/Dimitri Gerondidakis
The Dragon V2 spacecraft’s seating arrangement with the control panel swung up to allow crewmembers to get into their seats. Once the crew is in place, the control panel swings down and locks in launch position. Credit: NASA/Dimitri Gerondidakis

A look through the open hatch of the Dragon V2 reveals the layout and interior of the seven-crew capacity spacecraft. Credit: NASA/Dimitri Gerondidakis
A look through the open hatch of the Dragon V2 reveals the layout and interior of the seven-crew capacity spacecraft. Credit: NASA/Dimitri Gerondidakis

SpaceX CEO Elon Musk unveils SpaceX Dragon V2 next generation astronaut spacecraft on May 29, 2014.  Credit:  Robert Fisher/America Space
SpaceX CEO Elon Musk unveils SpaceX Dragon V2 next generation astronaut spacecraft on May 29, 2014. Credit: Robert Fisher/America Space

Boeing CST-100 Space Taxi Maiden Test Flight to ISS Expected Early 2017 – One on One Interview with Chris Ferguson, Last Shuttle Commander

Chris Ferguson, last Space Shuttle Atlantis commander, tests the Boeing CST-100 capsule which may fly US astronauts to the International Space Station in 2017. Ferguson is now Boeing’s director of Crew and Mission Operations for the Commercial Crew Program vying for NASA funding. Credit: NASA/Boeing

KENNEDY SPACE CENTER, FL – Boeing expects to launch the first unmanned test flight of their commercial CST-100 manned ‘space taxi’ in “early 2017,” said Chris Ferguson, commander of NASA’s final shuttle flight in an exclusive one-on-one interview with Universe Today for an inside look at Boeing’s space efforts. Ferguson is now spearheading Boeing’s human spaceflight capsule project as director of Crew and Mission Operations.

“The first unmanned orbital test flight is planned in January 2017 … and may go to the station,” Ferguson told me during a wide ranging, in depth discussion about a variety of human spaceflight topics and Boeing’s ambitious plans for their privately developed CST-100 human rated spaceship – with a little help from NASA.

Boeing has reserved a launch slot at Cape Canaveral with United Launch Alliance (ULA), but the details are not yet public.

If all goes well, the maiden CST-100 orbital test flight with humans would follow around mid-2017.

“The first manned test could happen by the end of summer 2017 with a two person crew,” he said.

“And we may go all the way to the space station.”

Boeing is among a trio of American aerospace firms, including SpaceX and Sierra Nevada Corp, vying to restore America’s capability to fly humans to Earth orbit and the space station by late 2017, using seed money from NASA’s Commercial Crew Program (CCP) in a public/private partnership. The next round of contracts will be awarded by NASA about late summer 2014.

That’s a feat that America hasn’t accomplished in nearly three years.

“It’s been over 1000 days and counting since we landed [on STS-135],” Ferguson noted with some sadness as he checked the daily counter on his watch. He is a veteran of three space flights.

Boeing has selected Florida to be the base for its commercial crew program office. Image Credit: Boeing
Boeing CST-100 commercial crew capsule approaches the ISS in this artist’s concept. Credit: Boeing

Since the shuttles retirement in July 2011 following touchdown of Space Shuttle Atlantis on the last shuttle flight (STS-135) with Ferguson in command, no American astronauts have launched to space from American soil on American rockets and spaceships.

The only ticket to the ISS and back has been aboard the Russian Soyuz capsule.

Chris and the Boeing team hope to change the situation soon. They are chomping at the bits to get Americas back into space from US soil and provide reliable and cost-effective US access to destinations in low Earth orbit like the ISS and the proposed private Bigelow space station.

Boeing wants to send its new private spaceship all the way to the space station starting on the very first unmanned and manned test flights currently slated for 2017, according to Ferguson.

“NASA wants us to provide [crew flight] services by November 2017,” said Ferguson, according to the terms of the CCP contact award.”

The CST-100 crew capsule awaits liftoff aboard an Atlas V launch vehicle at Cape Canaveral in this artist’s concept. Credit: Boeing
The Boeing CST-100 crew capsule awaits liftoff aboard an Atlas V launch vehicle at Cape Canaveral in this artist’s concept. Credit: Boeing

The CST-100 will launch atop a man rated Atlas V rocket and carry a mix of cargo and up to seven crew members to the ISS.

“So both the first unmanned and manned test flight will be in 2017. The first unmanned orbital flight test is currently set for January 2017. The first manned test could be end of summer 2017,” he stated.

I asked Chris to outline the mission plans for both flights.

“Our first flight, the CST-100 Orbital Flight Test – is scheduled to be unmanned.”

“Originally it was just going to be an on orbital test of the systems, with perhaps a close approach to the space station. But we haven’t precluded our ability to dock.

“So if our systems mature as we anticipate then we may go all the way and actually dock at station. We’re not sure yet,” he said.

So I asked whether he thinks the CST-100 will also go dock at the ISS on the first manned test flight?

“Yes. Absolutely. We want go to all the way to the space station,” Ferguson emphatically told me.

“For the 1st manned test flight, we want to dock at the space station and maybe spend a couple weeks there.”

“SpaceX did it [docking]. So we think we can too.”

“The question is can we make the owners of the space station comfortable with what we are doing. That’s what it really comes down to.”

“As the next year progresses and the design matures and it becomes more refined and we understand our own capability, and NASA understands our capabilities as the space station program gets more involved – then I’m sure they will put the same rigor into our plan as they did into the SpaceX and Orbital Sciences plans.”

“When SpaceX and Orbital [wanted to] come up for the grapple [rather than just rendezvous], NASA asked ‘Are these guys ready?’ That’s what NASA will ask us.”

“And if we [Boeing] are ready, then we’ll go dock at the station with our CST-100.”

“And if we’re not ready, then we’ll wait another flight and go to the station the next time. It’s just that simple.”

“We looked at it and this is something we can do.”

“There are a lot of ways we have to make NASA and ourselves happy. But as a company we feel we can go do it,” Ferguson stated.

Boeing CST-100 crew vehicle docks at the ISS. Credit: Boeing
Boeing CST-100 crew vehicle docks at the ISS. Credit: Boeing

So the future looks promising.

But the schedule depends entirely on NASA funding levels approved by Congress. And that vital funding has been rather short on supply. It has already caused significant delays to the start of the space taxi missions for all three companies contending for NASA’s commercial crew contracts because of the significant slashes to the agency’s CCP budget request, year after year.

In fact the schedule has slipped already 18 months to the right compared to barely a few years ago.

So I asked Chris to discuss the CCP funding cuts and resulting postponements – which significantly affected schedules for Boeing, SpaceX and Sierra Nevada.

Here it is in a nutshell.

“No Bucks, No Buck Rogers,” explained Ferguson.

“The original plan was to conduct both the unmanned and manned CST-100 test flights in 2015.”

“Originally, we would have flown the unmanned orbital test in the summer of 2015. The crewed test would have been at the end of 2015.”

“So both flights are now a full year and a half later.” Ferguson confirmed.

“For the presidents [CCP] funding requests for the past few years of roughly about $800 million, they [Congress] only approved about half. It was significantly less than the request.”

Now at this very moment Congress is deliberating NASA’s Fiscal 2015 budget.

NASA Administrator Charles Bolden has said he will beg Congress to approve full funding for the commercial crew program this year – on his hands and knees if necessary.

NASA’s final shuttle crew on STS-135 mission greets the media and shuttle workers during Atlantis rollover from the OPF-1 processing hanger to the VAB at KSC during May 2011.   From left: Rex Walheim, Shuttle Commander Christopher Ferguson, Douglas Hurley and Sandra Magnus. The all veteran crew will delivered the Raffaello multipurpose logistics module (MPLM), science supplies, provisions and space parts to the International Space Station (ISS). Credit: Ken Kremer - kenkremer.com
NASA’s final shuttle crew on STS-135 mission greets the media and shuttle workers during Atlantis rollover from the OPF-1 processing hanger to the VAB at KSC during May 2011. From left: Rex Walheim, Shuttle Commander Christopher Ferguson, Douglas Hurley and Sandra Magnus. The all veteran crew will delivered the Raffaello multipurpose logistics module (MPLM), science supplies, provisions and space parts to the International Space Station (ISS). Credit: Ken Kremer – kenkremer.com

Otherwise there will be further delays to the start of the space taxi missions. And the direct consequence is NASA would be forced to continue buying US astronaut rides from the Russians at $70 Million per seat. All against the backdrop of Russian actions in the Ukraine where deadly clashes potentially threaten US access to the ISS in a worst case scenario if the ongoing events spin even further out of control and the West ratchets up economic sanctions against Russia.

The CST-100 is designed to be a “simple ride up to and back from space,” Ferguson emphasized to me.

NASA’s 135th and final shuttle mission takes flight on July 8, 2011 at 11:29 a.m. from the Kennedy Space Center in Florida bound for the ISS and the high frontier with Chris Ferguson as Space Shuttle Commander. Credit: Ken Kremer/kenkremer.com
NASA’s 135th and final shuttle mission takes flight on July 8, 2011 at 11:29 a.m. from the Kennedy Space Center in Florida bound for the ISS and the high frontier with Chris Ferguson as Space Shuttle Commander. Credit: Ken Kremer/kenkremer.com

It is being designed at Boeing’s Houston Product Support Center in Texas.

In Part 2 of my interview, Chris Ferguson will discuss the details about the design, how and where the CST-100 capsule will be manufactured at a newly renovated, former space shuttle facility at NASA’s Kennedy Space Center in Florida.

Stay tuned here for Ken’s continuing Boeing, SpaceX, Orbital Sciences, commercial space, Orion, Curiosity, Mars rover, MAVEN, MOM and more planetary and human spaceflight news.

Ken Kremer

STS-135 Shuttle Commander Chris Ferguson (right) and Ken Kremer at emergency M-113 Tank Practice.  Chris brought a special public gift for science aboard the last shuttle mission. Chris and Ken discuss our mutual love of science in the weeks before Atlantis July 8 liftoff.  Credit: Ken Kremer
STS-135 Shuttle Commander Chris Ferguson (right) and Ken Kremer (Universe Today) meet at emergency M-113 Tank Practice during crew pre-launch events at the Kennedy Space Center in the weeks before Atlantis July 8, 2011 liftoff. Credit: Ken Kremer- kenkremer.com
Scale models of NASA’s Commercial Crew program vehicles and launchers; Boeing CST-100, Sierra Nevada Dream Chaser, SpaceX Dragon. Credit: Ken Kremer/kenkremer.com
Scale models of NASA’s Commercial Crew program vehicles and launchers; Boeing CST-100, Sierra Nevada Dream Chaser, SpaceX Dragon. Credit: Ken Kremer/kenkremer.com

SpaceX Makes Strides Towards 1st Stage Falcon Rocket Recovery during Space Station Launch

Blastoff of SpaceX Falcon 9 rocket from Cape Canaveral Air Force Station in Florida on April 18, 2014. Credit: Alan Walters/AmericaSpace

Blastoff of SpaceX Falcon 9 rocket from Cape Canaveral Air Force Station in Florida on April 18, 2014. Credit: Alan Walters/AmericaSpace
Story updated[/caption]

The powerful SpaceX Falcon 9 rocket that launched successfully on a cargo delivery run for NASA bound for the Space Station on Friday, April 18, from Cape Canaveral, Fla, also had a key secondary objective for the company aimed at experimenting with eventually recovering the rockets first stage via the use of landing legs and leading to the boosters refurbishment and reuse further down the road.

Marking a first of its kind test, this 20 story tall commercial Falcon 9 rocket was equipped with a quartet of landing legs to test controlled soft landing techniques first in the ocean and then back on solid ground at some later date this year or next – by reigniting the 1st stage engines for a guided touchdown.

The 12 foot diameter Falcon 9 rocket would sprout the legs just prior to water impact for the controlled soft landing in the Atlantic Ocean, guided by SpaceX engineers.

'Threading the needle', the Falcon 9/Dragon vehicle passes through the catenary lightning wires as it roars from the pad on the CRS-3 mission.  Credit: nasatech.net
‘Threading the needle’, the Falcon 9/Dragon vehicle passes through the catenary lightning wires as it roars from the pad on the CRS-3 mission. Credit: nasatech.net

Prior to the launch SpaceX managers were careful not to raise expectations.

“The entire recovery of the first stage is completely experimental,” said Hans Koenigsmann, SpaceX vice president of mission assurance. “It has nothing to do with the primary mission.”

He estimated the odds of successfully retrieving an intact booster at merely 30 or 40 percent.

Following Friday’s blastoff, SpaceX reported they made significant strides towards that goal of a 1st stage recovery.

1st stage of SpaceX Falcon 9 rocket equipped with landing legs and now scheduled for launch to the International Space Station on March 16, 2014 from Cape Canaveral, FL. Credit: SpaceX/Elon Musk
1st stage of SpaceX Falcon 9 rocket equipped with landing legs which launched to the International Space Station on April 18, 2014 from Cape Canaveral, FL. Credit: SpaceX/Elon Musk

SpaceX engineers had preprogrammed the spent first stage to relight several Merlin 1 D engines after completing the boost phase and stage seperation to stabilize it, reduce its roll rate and then gradually lower its altitude back down to the Atlantic Ocean’s surface for a soft landing attempt and later possible recovery by retrieval ships.

All these critical steps seemed to go fairly well in initial reports that are subject to change.

SpaceX CEO and founder Elon Musk reported at a post launch briefing and later tweeted further updates that the Falcon 9 first stage actually made a good water landing despite rough seas, with waves swelling at least six feet.

“Roll rate close to zero (v important!).”

“Data upload from tracking plane shows landing in Atlantic was good! Several boats enroute through heavy seas,” Musk tweeted.

Furthermore he reported that the 1st stage survived the ocean touchdown.

“Flight computers continued transmitting for 8 seconds after reaching the water. Stopped when booster went horizontal.”

Because of the high waves, the recovery boats had difficulty reaching the booster in the recovery area located some two hundred miles off shore from Cape Canaveral.

Several previous attempts by SpaceX to recover the first stage via parachutes and thrusters were not successful. So SpaceX adopted this new approach with the landing legs and 1st stage Merlin 1 D engines.

Further details will be proved when they become available.

SpaceX Falcon 9 rocket liftoff on April 18, 2014 from Space Launch Complex 40 at Cape Canaveral, Fla.  Credit: Julian Leek
SpaceX Falcon 9 rocket liftoff on April 18, 2014 from Space Launch Complex 40 at Cape Canaveral, Fla. Credit: Julian Leek

The attachment of the 25 foot long 1st stage landing legs to SpaceX’s next-generation Falcon 9 rocket for ocean recovery counts as a major step towards the firm’s future goal of building a fully reusable rocket and dramatically lowering launch costs compared to expendable boosters.

The eventual goal is to accomplish a successful first stage touchdown by the landing legs on solid ground back somewhere near on Cape Canaveral, Florida.

Musk said that SpaceX is still working out the details on finding a suitable landing location with NASA and the US Air Force.

SpaceX Falcon 9 rocket and Dragon resupply ship launch from the Cape Canaveral Air Force Station in Florida on April 18, 2014.   Credit:  Jeff Seibert/Wired4Space
SpaceX Falcon 9 rocket and Dragon resupply ship launch from the Cape Canaveral Air Force Station in Florida on April 18, 2014. Credit: Jeff Seibert/Wired4Space

Extensive work and testing remains to develop and refine the technology before a land landing will be attempted by the company, says Musk.

It will be left to future missions to accomplish a successful first stage touchdown by the landing legs back on solid ground back through a series of ramped up rocket tests at Cape Canaveral, Florida.

“Even though we probably won’t get the stage back, I think we’re really starting to connect the dots of what’s needed,” Musk said at the briefing.

“There are only a few more dots that need to be there to have it all work. I think we’ve got a decent chance of bringing a stage back this year, which would be wonderful.”

Overall Musk was very pleased with the performance of the rocket and the landing leg test.

“I would consider it a success in the sense that we were able to control the boost stage to a zero roll rate, which is previously what has destroyed the stage, an uncontrolled roll, where the on-board nitrogen thrusters weren’t able to control the aerodynamic torque and spun up.”

“This time, with more powerful thrusters and more nitrogen propellant, we were able to null the roll rates.”

“I’m feeling pretty excited,” Musk stated. “This is a happy day. Most important of all is that we did a good job for NASA.”

This extra powerful new version of the Falcon 9 dubbed v1.1 is powered by a cluster of nine of SpaceX’s new Merlin 1D engines that are about 50% more powerful compared to the standard Merlin 1C engines. The nine Merlin 1D engines 1.3 million pounds of thrust at sea level rises to 1.5 million pounds as the rocket climbs to orbit.

Therefore the upgraded Falcon 9 can boost a much heavier cargo load to the ISS, low Earth orbit, geostationary orbit and beyond.

Indeed Dragon is loaded with nearly 5000 pounds of cargo, about double the weight carried previously.

If all goes well, Dragon will reach the ISS early on Easter Sunday morning after a two day orbital chase.

Station crew members Rick Mastracchio and Steven Swanson will grapple the Dragon cargo freighter with the 57 foot long Canadarm2 on Easter Sunday at about 7:14 a.m. and then berth it at the Earth-facing port of the Harmony module.

NASA TV coverage of the Easter Sunday grappling process will begin at 5:45 a.m. with berthing coverage beginning at 9:30 a.m. : http://www.nasa.gov/ntv

Stay tuned here for Ken’s continuing SpaceX, Orbital Sciences, commercial space, Orion, Chang’e-3, LADEE, Mars rover, MAVEN, MOM and more planetary and human spaceflight news.

Ken Kremer

Rising slowly from Pad 40, the fully loaded Dragon and Falcon 9 v1.1 vehicle begin the mission to ISS. Credit: nasatech.net
Rising slowly from Pad 40, the fully loaded Dragon and Falcon 9 v1.1 vehicle begin the mission to ISS. Credit: nasatech.net

SpaceX Unveils Gorgeous Rocket Legs for Space Station Launch on March 16

The Falcon 9 rocket with landing legs in SpaceX’s hangar at Cape Canaveral, Fl, preparing to launch Dragon to the space station this Sunday March 30. Credit: SpaceX

SpaceX is nearly ready to Rock ‘n’ Roll with their first rocket sporting landing legs and slated to blast off this coming weekend carrying a commercial Dragon cargo freighter bound for the International Space Station (ISS).

Check out the Falcon 9 rockets gorgeous legs unveiled today by SpaceX in an eye popping new photo featured above.

The newly released image shows the private Falcon 9 positioned horizontally inside the Cape Canaveral processing hanger and looking up directly from the bottom of her legs and nine powerful first stage engines.

Following a brief static hotfire test this past weekend of all nine upgraded Merlin 1D engines powering the first stage of SpaceX’s next generation Falcon 9 rocket, the path is clear for Sunday’s (March 16) night time lift off at 4:41 a.m. EDT from Space Launch Complex 40 at Cape Canaveral Air Force Station in Florida.

This week, engineers working inside the hanger are loading the Dragon vessel with the final cargo items bound for the station that are time sensitive.

Engineers pack Dragon with cargo, including support for more than 150 science investigations on the ISS. Credit: SpaceX
Engineers pack Dragon with cargo, including support for more than 150 science investigations on the ISS. Credit: SpaceX

Altogether, this unmanned SpaceX CRS-3 mission will deliver over 5000 pounds of science experiments and essential gear, spare parts, crew provisions, food, clothing and supplies to the six person crews living and working aboard the ISS soaring in low Earth orbit under NASA’s Commercial Resupply Services (CRS) contract.

An upgraded SpaceX Falcon 9 rocket with Dragon cargo capsule bound for the ISS is slated to launch on March 16, 2014 from Space Launch Complex 40 at Cape Canaveral, FL.   File photo.  Credit: Ken Kremer/kenkremer.com
An upgraded SpaceX Falcon 9 rocket with Dragon cargo capsule bound for the ISS is slated to launch on March 16, 2014 from Space Launch Complex 40 at Cape Canaveral, FL. File photo. Credit: Ken Kremer/kenkremer.com

Dragon is carrying research cargo and equipment for over 150 science investigations, including 100 protein crystal experiments that will allow scientists to observe the growth of crystals in zero-G.

Conducted in the absence of gravity, these space experiments will help Earth bound researchers to potentially learn how to grow crystals of much larger sizes compared to here on Earth and afford scientists new insights into designing and developing new drugs and pesticides.

A batch of new student science experiments are also packed aboard and others will be returned at the end of the mission.

The attachment of landing legs to the first stage of SpaceX’s next-generation Falcon 9 rocket counts as a major first step towards the firm’s future goal of building a fully reusable rocket.

For this Falcon 9 flight, the rocket will sprout legs for a controlled soft landing in the Atlantic Ocean guided by SpaceX engineers.

“F9 will continue to land in the ocean until we prove precision control from hypersonic thru subsonic regimes,” says SpaceX CEO and founder Elon Musk.

It will be left to a future mission to accomplish a successful first stage touchdown by the landing legs on solid ground back at Cape Canaveral, Florida.

Much development works remains before a land landing will be attempted.

The Falcon will roll out from the hanger to Launch Pad 40 on Saturday, March 15.

Falcon 9 and Dragon static fire test on March 8, 2014. Credit: SpaceX
Falcon 9 and Dragon static fire test on March 8, 2014. Credit: SpaceX

SpaceX is under contract to NASA to deliver 20,000 kg (44,000 pounds) of cargo to the ISS during a dozen Dragon cargo spacecraft flights over the next few years at a cost of about $1.6 Billion.

To date SpaceX has completed two operational cargo resupply missions and a test flight to the station. The last flight dubbed CRS-2 blasted off a year ago on March 1, 2013 atop the initial version of the Falcon 9 rocket.

All four landing legs now mounted on Falcon 9 rocket being processed inside hanger at Cape Canaveral, FL for Mar 16 launch.  Credit: SpaceX/Elon Musk
All four landing legs now mounted on Falcon 9 rocket being processed inside hanger at Cape Canaveral, FL for Mar 16 launch. Credit: SpaceX/Elon Musk

Following the scheduled March 16 launch and a series of orbit raising and course corrections over the next two days, Dragon will rendezvous and dock at the Earth facing port on the station’s Harmony module on March 18.

The Harmony port was recently vacated by the Orbital Sciences built Cygnus cargo spacecraft to make way for Dragon.

This extra powerful new version of the Falcon 9 dubbed v1.1 is powered by a cluster of nine of SpaceX’s new Merlin 1D engines that are about 50% more powerful compared to the standard Merlin 1C engines. The nine Merlin 1D engines 1.3 million pounds of thrust at sea level rises to 1.5 million pounds as the rocket climbs to orbit.

Therefore the upgraded Falcon 9 can boost a much heavier cargo load to the ISS, low Earth orbit, geostationary orbit and beyond.

Indeed Dragon is loaded with about double the cargo weight carried previously.

The Merlin 1D engines are arrayed in an octaweb layout for improved efficiency.

SpaceX founder and CEO Elon Musk briefs reporters including Universe Today on Sunday (Nov. 24) in Cocoa Beach, FL prior to planned SpaceX Falcon 9 rocket blastoff with SES-8 communications satellite set for Nov. 25, 2013 from Cape Canaveral, FL. Credit: Ken Kremer/kenkremer.com
SpaceX founder and CEO Elon Musk briefs reporters including Universe Today in Cocoa Beach, FL prior to planned SpaceX Falcon 9 rocket blastoff with SES-8 communications satellite from Cape Canaveral, FL. Credit: Ken Kremer/kenkremer.com

Stay tuned here for Ken’s continuing SpaceX, Orbital Sciences, commercial space, Orion, Chang’e-3, LADEE, Mars rover, MAVEN, MOM and more planetary and human spaceflight news. Learn more at Ken’s upcoming presentations at the NEAF astro/space convention on April 12/13.

And watch for Ken’s upcoming SpaceX launch coverage at Cape Canaveral & the Kennedy Space Center press site.

Ken Kremer

NASA Pressing Towards Fall 2014 Orion Test Flight – Service Module Complete

Engineers prepare Orion’s service module for installation of the fairings that will protect it during launch this fall when Orion launches on its first mission. The service module, along with its fairings, is now complete. Credit: NASA

Engineers prepare Orion’s service module for installation of the fairings that will protect it during launch this fall when Orion launches on its first mission. The service module, along with its fairings, is now complete. Credit: NASA
Story Updated[/caption]

2014 is the Year of Orion.

Orion is NASA’s next human spaceflight vehicle destined for astronaut voyages beyond Earth and will launch for the first time later this year on its inaugural test flight from Cape Canaveral, Florida.

The space agency is rapidly pressing forward with efforts to finish building the Orion crew module slated for lift off this Fall on the unmanned Exploration Flight Test – 1 (EFT-1) mission.

NASA announced today that construction of the service module section is now complete.

NASA Administrator Charles Bolden and science chief Astronaut John Grunsfeld discusses NASA’s human spaceflight initiatives backdropped by the service module for the Orion crew capsule being assembled at the Kennedy Space Center.  Credit: Ken Kremer/kenkremer.com
NASA Administrator Charles Bolden and science chief Astronaut John Grunsfeld discuss NASA’s human spaceflight initiatives backdropped by the service module for the Orion crew capsule being assembled at the Kennedy Space Center. Credit: Ken Kremer/kenkremer.com

The Orion module stack is comprised of three main elements – the Launch Abort System (LAS) on top, the crew module (CM) in the middle and the service module (SM) on the bottom.

With the completion of the service module, two thirds of the Orion EFT-1 mission stack are now compete.

LAS assembly was finalized in December.

The crew module is in the final stages of construction and completion is due by early spring.

Orion is being manufactured at NASA’s Kennedy Space Center (KSC) inside a specially renovated high bay in the Operations and Checkout Building (O&C).

“We are making steady progress towards the launch in the fall,” said NASA Administrator Charles Bolden at a media briefing back dropped by the Orion service module inside the O&C facility.

“It’s very exciting because it signals we are almost there getting back to deep space and going much more distant than where we are operating in low Earth orbit at the ISS.”

“And I’m very excited for the young people who will have an opportunity to fly Orion,” Bolden told me in the O&C.

Lockheed Martin is the prime contractor for Orion under terms of a contract from NASA.

Orion is NASA’s first spaceship designed to carry human crews on long duration flights to deep space destinations beyond low Earth orbit, such as asteroids, the Moon, Mars and beyond.

The inaugural flight of Orion on the unmanned Exploration Flight Test – 1 (EFT-1) mission is on schedule to blast off from the Florida Space Coast in mid September 2014 atop a Delta 4 Heavy booster, Scott Wilson, NASA’s Orion Manager of Production Operations at KSC, told Universe Today during a recent interview at KSC.

Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) mock up stack inside the transfer aisle of the Vehicle Assembly Building (VAB) at the Kennedy Space Center (KSC) in Florida. Credit: Ken Kremer/kenkremer.com
Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) mock up stack inside the transfer aisle of the Vehicle Assembly Building (VAB) at the Kennedy Space Center (KSC) in Florida. Service Module at bottom. Credit: Ken Kremer/kenkremer.com

Orion is currently under development as NASA’s next generation human rated vehicle to replace the now retired space shuttle.

Concurrently, NASA’s commercial crew initiative is fostering the development of commercial space taxi’s to ferry US astronauts to low Earth orbit and the International Space Station (ISS).

Get the details in my interview with SpaceX CEO Elon Musk about his firm’s Dragon ‘space taxi’ launching aboard the SpaceX upgraded Falcon 9 boosterhere.

The two-orbit, four- hour EFT-1 flight will lift the Orion spacecraft and its attached second stage to an orbital altitude of 3,600 miles, about 15 times higher than the International Space Station (ISS) – and farther than any human spacecraft has journeyed in 40 years.

The crew module rests atop the service module, similar to the Apollo Moon landing program architecture.

Orion service module assembly in the Operations and Checkout facility at Kennedy Space Center.   Credit: Ken Kremer/kenkremer.com
Orion service module assembly in the Operations and Checkout facility at Kennedy Space Center. Credit: Ken Kremer/kenkremer.com

The SM provides in-space power, propulsion capability, attitude control, thermal control, water and air for the astronauts.

For the EFT-1 flight, the SM is not fully outfitted. It is a structural representation simulating the exact size and mass.

In a significant difference from Apollo, Orion is equipped with a trio of massive fairings that encase the SM and support half the weight of the crew module and the launch abort system during launch and ascent. The purpose is to improve performance by saving weight from the service module, thus maximizing the vehicles size and capability in space.

All three fairings are jettisoned at an altitude of 100 miles up when they are no longer need to support the stack.

The fairings that will protect it during launch are added to Orion’s service module at the Operations and Checkout facility at Kennedy Space Center.  Credit: NASA
The fairings that will protect it during launch are added to Orion’s service module at the Operations and Checkout facility at Kennedy Space Center. Credit: NASA

On the next Orion flight in 2017, the service module will be manufactured built by the European Space Agency (ESA).

“When we go to deep space we are not going alone. It will be a true international effort including the European Space Agency to build the service module,” said Bolden.

The new SM will be based on components from ESA’s Automated Transfer Vehicle (ATV) which is an unmanned resupply spacecraft used to deliver cargo to the ISS.

A key upcoming activity for the CM is installation of the thermal protection system, including the heat shield.

The heat shield is the largest one ever built. It arrived at KSC last month loaded inside NASA’s Super Guppy aircraft while I observed. Read my story – here.

The 2014 EFT-1 test flight was only enabled by the extremely busy and productive year of work in 2013 by the Orion EFT-1 team.

“There were many significant Orion assembly events ongoing on 2013” said Larry Price, Orion deputy program manager at Lockheed Martin, in an interview with Universe Today at Lockheed Martin Space Systems in Denver.

“This includes the heat shield construction and attachment, power on, installing the plumbing for the environmental and reaction control system, completely outfitting the crew module, attached the tiles and building the service module which finally leads to mating the crew and service modules (CM & SM) in early 2014,” Price told me.

Orion was originally planned to send American astronauts back to Moon – until Project Constellation was cancelled by the Obama Administration.

Now with Orion moving forward and China’s Yutu rover trundling spectacularly across the Moon, one question is which country will next land humans on the Moon – America or China?

Read my story about China’s manned Moon landing plans – here.

Stay tuned here for Ken’s continuing Orion, Chang’e-3, Orbital Sciences, SpaceX, commercial space, LADEE, Mars and more news.

Ken Kremer

Orion schematic. Credit: NASA
Orion schematic. Credit: NASA
NASA Administrator Charles Bolden meets the media including Ken Kremer/Universe Today to discuss NASA’s human spaceflight initiatives and Orion crew capsule being assembled at the Kennedy Space Center. Credit: Urijan Poerink
NASA Administrator Charles Bolden meets the media including Ken Kremer/Universe Today to discuss NASA’s human spaceflight initiatives and Orion crew capsule being assembled at the Kennedy Space Center. Credit: Urijan Poerink

Spirit Rover Landed on Mars 10 Years Ago Today

This bird's-eye view from August 2005 combines a self-portrait of the spacecraft deck and a panoramic mosaic of the Martian surface as viewed by NASA's Mars Exploration Rover Spirit. The rover's solar panels are still gleaming in the sunlight, having acquired only a thin veneer of dust two years after the rover landed and commenced exploring the red planet. Spirit captured this 360-degree panorama on the summit of "Husband Hill" inside Mars' Gusev Crater. During the period from Spirit's Martian days, or sols, 583 to 586 (Aug. 24 to 27, 2005), the rover's panoramic camera acquired the hundreds of individual frames for this largest panorama ever photographed by Spirit. Credit: NASA/JPL-Caltech/Cornell

Ten Years Ago, Spirit Rover Lands on Mars
This bird’s-eye view from August 2005 combines a self-portrait of the spacecraft deck and a panoramic mosaic of the Martian surface as viewed by NASA’s Mars Exploration Rover Spirit. The rover’s solar panels are still gleaming in the sunlight, having acquired only a thin veneer of dust two years after the rover landed and commenced exploring the red planet. Spirit captured this 360-degree panorama on the summit of “Husband Hill” inside Mars’ Gusev Crater. During the period from Spirit’s Martian days, or sols, 583 to 586 (Aug. 24 to 27, 2005), the rover’s panoramic camera acquired the hundreds of individual frames for this largest panorama ever photographed by Spirit. Credit: NASA/JPL-Caltech/Cornell
See Spirit’s 1st and last panoramas and more imagery below[/caption]

Today, Jan. 3, marks the 10th anniversary since the safe landing of NASA’s renowned Spirit rover on the plains of Mars on Jan. 3, 2004.

Spirit comprises one half of NASA’s now legendary pair of Mars Exploration Rovers (MER). Opportunity, her twin sister landed, on the opposite side of the Red Planet three weeks later – on Jan. 24, 2004. The goal was to “follow the water” as a potential enabler for past Martian microbes if they ever existed.

Together, the long-lived, golf cart sized robots proved that early Mars was warm and wet, billions of years ago – a key finding in the search for habitats conducive to life beyond Earth.

Exactly a decade ago, the famous robot survived the scorching atmospheric heating of the 6 minute plunge through the thin Martian atmosphere, bounced some two dozen times cocooned inside cushioning airbags, and gradually rolled to a stop inside 100 mile wide Gusev Crater. It was known as the “6 minutes of Terror”.

The three petaled landing pad opened and Spirit was dramatically born in a milestone event that will be forever remembered in the annuls of history because of the groundbreaking scientific discoveries that ensued and the unbelievable longevity of the twins.

Ten Years Ago, Spirit Rover Lands on Mars . This mosaic image taken on Jan. 4, 2004, by the navigation camera on the Mars Exploration Rover Spirit, shows a 360 degree panoramic view of the rover on the surface of Mars.   Spirit operated for more than six years after landing in January 2004 for what was planned as a three-month mission. Credit: NASA/JPL
Ten Years Ago, Spirit Rover Lands on Mars
This mosaic image taken on Jan. 4, 2004, by the navigation camera on the Mars Exploration Rover Spirit, shows a 360 degree panoramic view of the rover on the surface of Mars. Spirit operated for more than six years after landing in January 2004 for what was planned as a three-month mission. Credit: NASA/JPL

Before they were launched atop Delta II rockets in the summer of 2003 from Cape Canaveral, the dynamic, solar powered robo duo were expected to last a mere three months – with a ‘warranty’ of 90 Martian days (Sols).

Either dust accumulation on the life giving solar panels, an engineering issue or the extremely harsh Martian environment was expected to somehow terminate them mercilessly.

In reality, both robots enormously exceeded expectations and accumulated a vast bonus time of exploration and discovery in numerous extended mission phases.

'McMurdo' Panorama from Spirit's 'Winter Haven' . This beautiful scene reveals a tremendous amount of detail in Spirit's surroundings at a place called "Winter Haven," where the rover spent many months parked on a north-facing slope in order to keep its solar panels pointed toward the sun for the winter. During this time, it captured several images to create this high resolution panorama. During that time, while the rover spent the daylight hours conducting as much scientific research as possible, science team members assigned informal names to rock outcrops, boulders, and patches of soil commemorating exploration sites in Antarctica and the southernmost islands of South America. Antarctic bases are places where researchers, like the rovers on Mars, hunker down for the winter in subzero temperatures. During the past Martian winter, Spirit endured temperatures lower than minus 100 degrees Celsius (minus 148 degrees Fahrenheit). Credit: NASA/JPL/Cornell
‘McMurdo’ Panorama from Spirit’s ‘Winter Haven’
This beautiful scene reveals a tremendous amount of detail in Spirit’s surroundings at a place called “Winter Haven,” where the rover spent many months parked on a north-facing slope in order to keep its solar panels pointed toward the sun for the winter. During this time, it captured several images to create this high resolution panorama. During that time, while the rover spent the daylight hours conducting as much scientific research as possible, science team members assigned informal names to rock outcrops, boulders, and patches of soil commemorating exploration sites in Antarctica and the southernmost islands of South America. Antarctic bases are places where researchers, like the rovers on Mars, hunker down for the winter in subzero temperatures. During the past Martian winter, Spirit endured temperatures lower than minus 100 degrees Celsius (minus 148 degrees Fahrenheit). Credit: NASA/JPL/Cornell

No one foresaw that Martian winds would occasionally clean the solar panels to give them a new lease on life or that the components would miraculously continue functioning.

Spirit endured the utterly extreme Red Planet climate for more than six years until communications ceased in 2010.

Opportunity is still roving Mars today, and doing so in rather good condition!

Altogether, Spirit drove 4.8 miles (7.73 kilometers),that’s about 12 times more than the original goal set for the mission.

She transmitted over 128,000 images.

After landing in the dusty plains, she headed for the nearby Columbia Hills some 2 miles away and ultimately became the first Martian mountaineer, when she scaled Husband Hill and found evidence for the flow of liquid water at the Hillary outcrop.

Spirit acquired this mosaic on Sol 1202  (May 21, 2007), while investigating the area east of the elevated plateau known as "Home Plate" in the "Columbia Hills." The mosaic shows an area of disturbed soil, nicknamed "Gertrude Weise" by scientists, made by Spirit's stuck right front wheel. The trench exposed a patch of nearly pure silica, with the composition of opal. It could have come from either a hot-spring environment or an environment called a fumarole, in which acidic, volcanic steam rises through cracks. Either way, its formation involved water, and on Earth, both of these types of settings teem with microbial life. Credit: NASA/JPL-Caltech/Cornell
Spirit acquired this mosaic on Sol 1202 (May 21, 2007), while investigating the area east of the elevated plateau known as “Home Plate” in the “Columbia Hills.” The mosaic shows an area of disturbed soil, nicknamed “Gertrude Weise” by scientists, made by Spirit’s stuck right front wheel. The trench exposed a patch of nearly pure silica, with the composition of opal. It could have come from either a hot-spring environment or an environment called a fumarole, in which acidic, volcanic steam rises through cracks. Either way, its formation involved water, and on Earth, both of these types of settings teem with microbial life. Credit: NASA/JPL-Caltech/Cornell

The rovers were not designed to climb hills. But eventually she scaled 30 degree inclines.

The rover was equipped with a rock grinder named the Rock Abrasion Tool (RAT) built by Honeybee Robotics.

Spirit ground the surfaces off 15 rock targets and scoured 92 targets with a brush to prepare the targets for inspection with spectrometers and a microscopic imager, according to NASA.

Eventually she drove back down the hill and made even greater scientific discoveries in the area known as ‘Home Plate’.

Spirit survived three harsh Martian winters and only succumbed to the Antarctic-like temperatures when she unexpectedly became mired in an unseen sand trap driving beside an ancient volcanic feature named ‘Home Plate’ that prevented the solar arrays from generating life giving power to safeguard critical electronic and computer components.

In 2007, Spirit made one of the key discoveries of the mission at ‘Home Plate’ when her stuck right front wheel churned up a trench of bright Martian soil that exposed a patch of nearly pure silica, which was formed in a watery hot spring or volcanic environment.

Spirit was heading towards another pair of volcanic objects named ‘von Braun’ and ‘Goddard’ and came within just a few hundred feet when she died in the sand trap.

See Spirits last panorama below – created from raw images taken in Feb. 2010 by Marco Di Lorenzo and Ken Kremer.

Last View from Spirit rover on Mars.  Spirit’s last panorama from Gusev Crater was taken during February 2010 before her death from extremely low temperatures during her 4th Martian winter.  Spirit was just 500 feet from her next science target - dubbed Von Braun – at center, with Columbia Hills as backdrop.  Mosaic Credit: Marco Di Lorenzo/ Kenneth Kremer/ NASA/JPL/Cornell University.  Mosaic featured on Astronomy Picture of the Day (APOD) on 30 May 2011 - http://apod.nasa.gov/apod/ap110530.html
Last View from Spirit rover on Mars
Spirit’s last panorama from Gusev Crater was taken during February 2010 before her death from extremely low temperatures during her 4th Martian winter. Spirit was just 500 feet from her next science target – dubbed Von Braun – at center, with Columbia Hills as backdrop. Mosaic Credit: Marco Di Lorenzo/ Kenneth Kremer/ NASA/JPL/Cornell University. Mosaic featured on Astronomy Picture of the Day (APOD) on 30 May 2011 – http://apod.nasa.gov/apod/ap110530.html

Here’s how the rovers’ principal investigator, Steve Squyres of Cornell University, Ithaca, N.Y., described some of the key findings in a NASA statement, starting with what Spirit found after driving from the crater floor where it landed into the Columbia hills to the east:

“In the Columbia Hills, we discovered compelling evidence of an ancient Mars that was a hot, wet, violent place, with volcanic explosions, hydrothermal activity, steam vents — nothing like Mars today.

“At Opportunity’s landing site, we found evidence of an early Mars that had acidic groundwater that sometimes reached the surface and evaporated away, leaving salts behind. It was an environment with liquid water, but very different from the environment that Spirit told us about.

“When Opportunity got to the rim of Endeavour Crater, we began a whole new mission. We found gypsum veins and a rich concentration of clay minerals. The clay minerals tell us about water chemistry that was neutral, instead of acidic — more favorable for microbial life, if any ever began on Mars.”

“Because of the rovers’ longevity, we essentially got four different landing sites for the price of two.”

MER10-SpiritAndOpportunity_ByTheNumbers[1]

Meanwhile, NASA’s new Curiosity rover just celebrated 500 Sols on Mars and is speeding towards Mount Sharp from inside Gale Crater – which is about the same size as Gusev crater.

And a pair of newly launched orbiters are streaking to the Red Planet; NASA’s MAVEN and India’s MOM.

And China’s new Yutu lunar rover and Chang’e-3 lander are napping through the lunar night until mid-January.

Stay tuned here for Ken’s continuing Curiosity, Chang’e-3, SpaceX, Orbital Sciences, LADEE, MAVEN, Mars rover and MOM news.

Ken Kremer

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Learn more about Curiosity, MAVEN, MOM, Mars rovers, SpaceX, Orbital Sciences Antares Jan. 8 launch, and more at Ken’s upcoming presentations

Jan 6-8: “Antares/Cygnus ISS Rocket Launch from Virginia on Jan. 8” & “Space mission updates”; Rodeway Inn, Chincoteague, VA, evening

Orion takes shape for 2014 Test Flight

Technicians work on mockups of the Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) to simulate critical assembly techniques inside the Vehicle Assembly Building (VAB) at NASA’s Kennedy Space Center (KSC) in Florida for the EFT-1 mission due to liftoff in September 2014. Credit: Ken Kremer/kenkremer.com

KENNEDY SPACE CENTER, FL – NASA is picking up the pace of assembly operations for the Orion capsule, America’s next crew vehicle destined to carry US astronauts to Asteroids, the Moon, Mars and Beyond.

Just over a year from now in September 2014, NASA will launch Orion on its first test flight, an unpiloted mission dubbed EFT-1.

At NASA’s Kennedy Space Center in Florida, expert work crews are already hard at work building a myriad of Orion’s key components, insuring the spacecraft takes shape for an on time liftoff.

Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) stack inside the transfer aisle of the Vehicle Assembly Building (VAB) at the Kennedy Space Center (KSC) in Florida.  Powerful quartet of LAS abort motors will fire in case of launch emergency to save astronauts lives.  Credit: Ken Kremer/kenkremer.com
Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) stack inside the transfer aisle of the Vehicle Assembly Building (VAB) at the Kennedy Space Center (KSC) in Florida. Powerful quartet of LAS abort motors will fire in case of launch emergency to save astronauts lives. Credit: Ken Kremer/kenkremer.com
Universe Today is reporting on NASA’s progress and I took an exclusive behind the scenes tour inside KSC facilities to check on Orion’s progress.

In 2014 Orion will blast off to Earth orbit atop a mammoth Delta IV Heavy booster, the most powerful booster in America’s rocket fleet following the retirement of NASA’s Space Shuttle orbiters in 2011.

On later flights Orion will blast off on the gargantuan Space Launch System (SLS), the world’s most powerful rocket which is simultaneously under development by NASA.

At the very top of the Orion launch stack sits the Launch Abort System (LAS) – a critically important component to ensure crew safety, bolted above the crew module.

In case of an emergency situation, the LAS is designed to ignite within milliseconds to rapidly propel the astronauts inside the crew module away from the rocket and save the astronauts lives.

The LAS is one of the five primary components of the flight test vehicle for the EFT-1 mission.

Astronaut hatch swung open on Orion capsule mock up joined to base of Launch Abort System (LAS) emergency escape tower.   Credit: Ken Kremer/kenkremer.com
Astronaut hatch swung open on Orion capsule mock up joined to base of Launch Abort System (LAS) emergency escape tower. Credit: Ken Kremer/kenkremer.com

Prior to any launch from the Kennedy Space Center, all the rocket components are painstakingly attached piece by piece.

Final assembly for EFT-1 takes place inside the iconic Vehicle Assembly Building (VAB).

To get a head start on assembly with the launch date relentlessly approaching, technicians have been practicing lifting and stacking techniques for several months inside the VAB transfer aisle using the 6 ton LAS pathfinder replica and mock ups of the Orion crew and service modules.

This 175 ton hook and crane system used to maneuver the Orion crew capsule, Service Module and Launch Abort System (LAS) components inside the Vehicle Assembly Building the Kennedy Space Center (KSC) in Florida. Credit: Ken Kremer/kenkremer.com
This 175 ton hook and crane system used to maneuver the Orion crew capsule, Service Module and Launch Abort System (LAS) components inside the Vehicle Assembly Building the Kennedy Space Center (KSC) in Florida. Credit: Ken Kremer/kenkremer.com

Conducting the practice sessions now with high fidelity replicas serves multiple purposes, including anticipating and solving problems now before the real equipment arrives, as well as to keep the teams proficient between the years long launch gap between the finale of the Space Shuttle program and the start up of the Orion/SLS deep space exploration program.

Delicate maneuvers like lifting, rolling, rotating, stacking, gimballing and more of heavy components requiring precision placements is very demanding and takes extensive practice to master.

There is no margin for error. Human lives hang in the balance.

Technicians at work practicing de-stacking operations with full size mockups of the Orion capsule and Launch Abort System components inside the Vehicle Assembly Building at the Kennedy Space Center in Florida. Credit: /Jim Grossmann
Technicians at work practicing de-stacking operations with full size mockups of the Orion capsule and Launch Abort System components inside the Vehicle Assembly Building at the Kennedy Space Center in Florida. Credit: NASA/Jim Grossmann

The same dedicated crews that assembled NASA’s Space Shuttles inside the VAB for 3 decades are assembling Orion. And they are using the same equipment.

“The breakover, taking the LAS from horizontal to vertical, is not as easy as it sometimes seems, but the VAB guys are exceptional, they are really good at what they do so they really didn’t have a problem,” says Douglas Lenhardt, who is overseeing the Orion mock-up and operations planning for the Ground Systems Development and Operations program, or GSDO.

Simulations with computer models are extremely helpful, but real life situations can be another matter.

“Real-life, things don’t always work perfectly and that’s why it really does help having a physical model,” says Lenhardt.

One day our astronauts will climb through an Orion hatch like this for America’s ‘Return to the Moon’ - following in the eternal footsteps of Apollo 11’s Neil Armstrong and Buzz Aldrin.  Credit: Ken Kremer/kenkremer.com
One day our astronauts will climb through an Orion hatch like this for America’s ‘Return to the Moon’ – following in the eternal footsteps of Apollo 11’s Neil Armstrong and Buzz Aldrin.
Credit: Ken Kremer/kenkremer.com

During the unmanned Orion EFT-1 mission, the capsule will fly on a two orbit test flight to an altitude of 3,600 miles above Earth’s surface, farther than any human spacecraft has gone in 40 years.

Ken Kremer

Orion soars skyward in 2014 for the first time. Credit: Ken Kremer/kenkremer.com
Orion soars skyward in 2014 for the first time.
Credit: Ken Kremer/kenkremer.com