Michoud Assembly Facility Archives

August 13, 2015December 23, 2015 by Ken Kremer

Milestone Test Firing of NASA’s SLS Monster Rocket Engine Advances Human Path to Deep Space

During a 535-second test on August 13, 2015, operators ran the Space Launch System (SLS) RS-25 rocket engine through a series of tests at different power levels to collect engine performance data on the A-1 test stand at NASA’s Stennis Space Center near Bay St. Louis, Mississippi. Credit: NASA
Story/imagery updated
See video below of full duration hot-fire test[/caption]

With today’s (Aug. 13) successful test firing of an RS-25 main stage engine for NASA’s Space Launch System (SLS) monster rocket currently under development, the program passed a key milestone advancing the agency on the path to propel astronauts back to deep space at the turn of the decade.

The 535 second long test firing of the RS-25 development engine was conducted on the A-1 test stand at NASA’s Stennis Space Center near Bay St. Louis, Mississippi – and ran for the planned full duration of nearly 9 minutes, matching the time they will fire during an actual SLS launch.

All indications are that the hot fire test apparently went off without a hitch, on first look.

“We ran the full duration and met all test objectives,” said Steve Wofford, SLS engine manager, on NASA TV following today’s’ test firing.

“There were no anomalies.” – based on the initial look.

The RS-25 is actually an upgraded version of former space shuttle main engines that were used with a 100% success rate during NASA’s three decade-long Space Shuttle program to propel the now retired shuttle orbiters to low Earth orbit. Those same engines are now being modified for use by the SLS.

Spectators enjoy the view during the Aug. 13, 2015 test firing of the RS-25 engine for NASA’s Space Launch System (SLS) on the A-1 test stand at NASA's Stennis Space Center near Bay St. Louis, Mississippi. Credit: NASA — Spectators enjoy the view during the Aug. 13, 2015 test firing of the RS-25 engine for NASA’s Space Launch System (SLS) on the A-1 test stand at NASA’s Stennis Space Center near Bay St. Louis, Mississippi. Credit: NASA

“Data collected on performance of the engine at the various power levels will aid in adapting the former space shuttle engines to the new SLS vehicle mission requirements, including development of an all-new engine controller and software,” according to NASA officials .

The engine controller functions as the “brain” of the engine, which checks engine status, maintains communication between the vehicle and the engine and relays commands back and forth.

The core stage (first stage) of the SLS will be powered by four RS-25 engines and a pair of the five-segment solid rocket boosters that will generate a combined 8.4 million pounds of liftoff thrust, making it the most powerful rocket the world has ever seen.

Since shuttle orbiters were equipped with three space shuttle main engines, the use of four RS-25s on the SLS represents another significant change that also required many modifications being thoroughly evaluated as well.

RS-25 test firing in progress on the A-1 test stand at NASA's Stennis Space Center near Bay St. Louis, Mississippi, on Aug. 13, 2015. Credit: NASA — RS-25 test firing in progress on the A-1 test stand at NASA’s Stennis Space Center near Bay St. Louis, Mississippi, on Aug. 13, 2015. Credit: NASA

The SLS will be some 10 percent more powerful than the Saturn V rockets that propelled astronauts to the Moon, including Neil Armstrong, the human to walk on the Moon during Apollo 11 in July 1969.

SLS will loft astronauts in the Orion capsule on missions back to the Moon by around 2021, to an asteroid around 2025 and then beyond on a ‘Journey to Mars’ in the 2030s – NASA’s overriding and agency wide goal.

Each of the RS-25’s engines generates some 500,000 pounds of thrust. They are fueled by cryogenic liquid hydrogen and liquid oxygen. For SLS they will be operating at 109% of power, compared to a routine usage of 104.5% during the shuttle era. They measure 14 feet tall and 8 feet in diameter.

They have to withstand and survive temperature extremes ranging from -423 degrees F to more than 6000 degrees F.

This video shows the full duration hot-fire test:

NASA has 16 of the RS-25s leftover from the shuttle era and they are all being modified and upgraded for use by the SLS rocket.

Today’s test was the sixth in a series of seven to qualify the modified engines to flight status. The engine ignited at 5:01 p.m. EDT and reached the full thrust level of 512,000 pounds within about 5 seconds.

The hot gas was exhausted out of the nozzle at 13 times the speed of sound.

Since the shuttle engines were designed and built over three decades ago, they are being modified where possible with state of the art components to enhance performance, functionality and ease of operation, by prime contractor Aerojet-Rocketdyne of Sacramento, California.

One of the key objectives of today’s engine firing and the entire hot fire series was to test the performance of a brand new engine controller assembled with modern manufacturing techniques.

“Operators on the A-1 Test Stand at Stennis are conducting the test series to qualify an all-new engine controller and put the upgraded former space shuttle main engines through the rigorous temperature and pressure conditions they will experience during a SLS mission,” says NASA.

“The new controller, or “brain,” for the engine, which monitors engine status and communicates between the vehicle and the engine, relaying commands to the engine and transmitting data back to the vehicle. The controller also provides closed-loop management of the engine by regulating the thrust and fuel mixture ratio while monitoring the engine’s health and status.’

Video caption: RS-25 – The Ferrari of Rocket Engines explained. Credit: NASA

“The RS-25 is the most complicated rocket engine out there on the market, but that’s because it’s the Ferrari of rocket engines,” says Kathryn Crowe, RS-25 propulsion engineer.

“When you’re looking at designing a rocket engine, there are several different ways you can optimize it. You can optimize it through increasing its thrust, increasing the weight to thrust ratio, or increasing its overall efficiency and how it consumes your propellant. With this engine, they maximized all three.”

Engineers will now pour over the data collected from hundreds of data channels in great detail to thoroughly analyze the test results. They will incorporate any findings into future test firings of the RS-25s.

NASA says that testing of RS-25 flight engines is set to start later this fall.

“The RS-25 engine gives SLS a proven, high performance, affordable main propulsion system for deep space exploration. It is one of the most experienced large rocket engines in the world, with more than a million seconds of ground test and flight operations time.”

NASA plans to buy completely new sets of RS-25 engines from Aerojet-Rocketdyne taking full advantage of technological advances and modern manufacturing techniques as well as lessons learned from this hot fire series of engine tests.

The maiden test flight of the SLS is targeted for no later than November 2018 and will be configured in its initial 70-metric-ton (77-ton) version with a liftoff thrust of 8.4 million pounds. It will boost an unmanned Orion on an approximately three week long test flight beyond the Moon and back.

Artist concept of the SLS Block 1 configuration. Credit: NASA

NASA plans to gradually upgrade the SLS to achieve an unprecedented lift capability of 130 metric tons (143 tons), enabling the more distant missions even farther into our solar system.

The first SLS test flight with the uncrewed Orion is called Exploration Mission-1 (EM-1) and will launch from Launch Complex 39-B at the Kennedy Space Center.

NASA’s first Orion spacecraft blasts off at 7:05 a.m. atop United Launch Alliance Delta 4 Heavy Booster at Space Launch Complex 37 (SLC-37) at Cape Canaveral Air Force Station in Florida on Dec. 5, 2014. Credit: Ken Kremer - kenkremer.com — NASA’s first Orion spacecraft blasts off at 7:05 a.m. atop United Launch Alliance Delta 4 Heavy Booster at Space Launch Complex 37 (SLC-37) at Cape Canaveral Air Force Station in Florida on Dec. 5, 2014. Credit: Ken Kremer – kenkremer.com

Orion’s inaugural mission dubbed Exploration Flight Test-1 (EFT) was successfully launched on a flawless flight on Dec. 5, 2014 atop a United Launch Alliance Delta IV Heavy rocket Space Launch Complex 37 (SLC-37) at Cape Canaveral Air Force Station in Florida.

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

Ken Kremer

NASA Administrator Charles Bolden officially unveils world’s largest welder to start construction of core stage of NASA's Space Launch System (SLS) rocket at NASA Michoud Assembly Facility, New Orleans, on Sept. 12, 2014. SLS will be the world’s most powerful rocket ever built. Credit: Ken Kremer - kenkremer.com — NASA Administrator Charles Bolden officially unveils world’s largest welder to start construction of core stage of NASA’s Space Launch System (SLS) rocket at NASA Michoud Assembly Facility, New Orleans, on Sept. 12, 2014. SLS will be the world’s most powerful rocket ever built. Credit: Ken Kremer – kenkremer.com

STS-135: Last launch using RS-25 engines that will now power NASA’s SLS deep space exploration rocket. 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

January 15, 2015December 23, 2015 by Ken Kremer

First SLS Engine Blazes to Life in Mississippi Test Firing Igniting NASA’s Path to Deep Space

The RS-25 engine fires up for a 500-second test Jan. 9, 2015 at NASA's Stennis Space Center near Bay St. Louis, Mississippi. Credit: NASA

NASA’s goal of sending astronauts to deep space took a major step forward when the first engine of the type destined to power the mighty Space Launch System (SLS) exploration rocket blazed to life during a successful test firing at the agency’s Stennis Space Center near Bay St. Louis, Mississippi.

The milestone hot fire test conducted on Jan. 9, involved igniting a shuttle-era RS-25 space shuttle main engine for 500 seconds on the A-1 test stand at Stennis.

A quartet of RS-25s, formerly used to power the space shuttle orbiters, will now power the core stage of the SLS which will be the most powerful rocket the world has ever seen.

“The RS-25 is the most efficient engine of its type in the world,” said Steve Wofford, manager of the SLS Liquid Engines Office at NASA’s Marshall Space Flight Center, in Huntsville, Alabama, where the SLS Program is managed. “It’s got a remarkable history of success and a great experience base that make it a great choice for NASA’s next era of exploration.”

The SLS is NASA’s mammoth heavy lift rocket now under development. It is intended to launch the Orion deep space crew capsule and propel astronauts aboard to destinations far beyond Earth and farther into space than ever before possible – beyond the Moon, to Asteroids and Mars.

The over eight minute RS-25 engine test firing provided NASA engineers with critical data on the engine controller unit, which is the “brain” of the engine providing communications between the engine and the vehice, and inlet pressure conditions.

“The controller also provides closed-loop management of the engine by regulating the thrust and fuel mixture ratio while monitoring the engine’s health and status. The new controller will use updated hardware and software configured to operate with the new SLS avionics architecture,” according to NASA.

This also marked the first test of a shuttle-era RS-25 since the conclusion of space shuttle main engine testing in 2009.

For the SLS, the RS-25 will be configured and operated differently from their use when attached as a trio to the base of the orbiters during NASA’s four decade long Space Shuttle era that ended with the STS-135 mission in July 2011.

“We’ve made modifications to the RS-25 to meet SLS specifications and will analyze and test a variety of conditions during the hot fire series,” said Wofford

“The engines for SLS will encounter colder liquid oxygen temperatures than shuttle; greater inlet pressure due to the taller core stage liquid oxygen tank and higher vehicle acceleration; and more nozzle heating due to the four-engine configuration and their position in-plane with the SLS booster exhaust nozzles.”

Watch this video of the RS-25 engine test:

Video Caption: The RS-25 engine that will drive NASA’s new rocket, the Space Launch System, to deep space blazed through its first successful test Jan. 9 at the agency’s Stennis Space Center near Bay St. Louis, Mississippi. Credit: NASA TV

The SLS core stage stores the cryogenic liquid hydrogen and liquid oxygen that fuel the RS-25 first stage engines.

“This first hot-fire test of the RS-25 engine represents a significant effort on behalf of Stennis Space Center’s A-1 test team,” said Ronald Rigney, RS-25 project manager at Stennis.

“Our technicians and engineers have been working diligently to design, modify and activate an extremely complex and capable facility in support of RS-25 engine testing.”

The Jan. 9 engine test was just the first of an extensive series planned. After an upgrade to the high pressure cooling system, an initial series of eight development tests will begin in April 2015 totaling 3,500 seconds of firing time.

A close-up view of the RS-25 engine from the test stand. Credit: NASA

The SLS core stage is being built at NASA’s Michoud Assembly Facility in New Orleans.

On Sept. 12, 2014, NASA Administrator Charles Bolden officially unveiled the world’s largest welder at Michoud, that will be used to construct the core stage, as I reported earlier during my on-site visit.

“This rocket is a game changer in terms of deep space exploration and will launch NASA astronauts to investigate asteroids and explore the surface of Mars while opening new possibilities for science missions, as well,” said NASA Administrator Charles Bolden during the ribbon-cutting ceremony at Michoud.

The core stage towers over 212 feet (64.6 meters) tall and sports a diameter of 27.6 feet (8.4 m).

NASA plans to gradually upgrade the SLS to achieve an unprecedented lift capability of 130 metric tons (143 tons), enabling the more distant missions even farther into our solar system.

The first SLS test flight with the uncrewed Orion is called Exploration Mission-1 (EM-1) and will launch from Launch Complex 39-B at the Kennedy Space Center.

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

Ken Kremer

September 28, 2014December 23, 2015 by Ken Kremer

Assembly Completed on Powerful Delta IV Rocket Boosting Maiden Orion Capsule Test Flight

A United Launch Alliance technician monitors the core booster elements of a Delta IV Heavy rocket after being integrated in preparation for Exploration Flight Test-1 at Space Launch Complex 37 on Cape Canaveral Air Force Station. Credit: Ken Kremer/kenkremer.com

CAPE CANAVERAL AIR FORCE STATION, FL – Assembly of the powerful Delta IV rocket boosting the pathfinder version of NASA’s Orion crew capsule on its maiden test flight in December has been completed.

Orion is NASA’s next generation human rated vehicle that will eventually carry America’s astronauts beyond Earth on voyages venturing farther into deep space than ever before – beyond the Moon to Asteroids, Mars and other destinations in our Solar System.

The state-of-the-art Orion spacecraft is scheduled to launch on its inaugural uncrewed mission, dubbed Exploration Flight Test-1 (EFT-1), in December 2014 atop the Delta IV Heavy rocket. It replaces NASA’s now retired space shuttle orbiters.

The triple barreled Delta IV Heavy is currently the most powerful rocket in America’s fleet following the retirement of the NASA’s Space Shuttle program.

Engineers from the rocket’s manufacturer – United Launch Alliance (ULA) – took a major step forward towards Orion’s first flight when they completed the integration of the three primary core elements of the rockets first stage with the single engine upper stage.

These three RS-68 engines will power each of the attached Delta IV Heavy Common Booster Cores (CBCs) the will launch NASA’s maiden Orion on the EFT-1 mission in December 2014. Credit: Ken Kremer/kenkremer.com — These three RS-68 engines will power each of the attached Delta IV Heavy Common Booster Cores (CBCs) that will launch NASA’s maiden Orion on the EFT-1 mission in December 2014. Credit: Ken Kremer/kenkremer.com

All of the rocket integration work and preflight processing took place inside ULA’s Horizontal Integration Facility (HIF), at Cape Canaveral Air Force Station in Florida.

Universe Today recently visited the Delta IV booster during an up close tour inside the HIF facility last week where the rocket was unveiled to the media in a horizontally stacked configuration. See my Delta IV photos herein.

The HIF building is located at Space Launch Complex 37 (SLC-37), on Cape Canaveral, a short distance away from the launch pad where the Orion EFT-1 mission will lift off on Dec. 4.

“The day-to-day processing is performed by ULA,” said Merri Anne Stowe of NASA’s Fleet Systems Integration Branch of the Launch Services Program (LSP), in a NASA statement.

“NASA’s role is to keep a watchful eye on everything and be there to help if any issues come up.”

The first stage is comprised of a trio of three Delta IV Common Booster Cores (CBCs).

Side view shows trio of Common Booster Cores (CBCs) with RS-68 engines powering the Delta IV Heavy rocket resting horizontally in ULA’s HIF processing facility at Cape Canaveral that will launch NASA’s maiden Orion on the EFT-1 mission in December 2014 from Launch Complex 37. Credit: Ken Kremer/kenkremer.com

Each CBC measures 134 feet in length and 17 feet in diameter. They are equipped with an RS-68 engine powered by liquid hydrogen and liquid oxygen propellants producing 656,000 pounds of thrust. Together they generate 1.96 million pounds of thrust.

This past spring I visited the HIF after the first two CBCs arrived by barge from their ULA assembly plant in Decatur, Alabama, located about 20 miles west of Huntsville.

The first CBC booster was attached to the center booster in June. The second one was attached in early August, according to ULA.

“After the three core stages went through their initial inspections and processing, the struts were attached, connecting the booster stages with the center core,” Stowe said. “All of this takes place horizontally.”

The Delta IV cryogenic second stage testing and attachment was completed in August and September. It measures 45 feet in length and 17 feet in diameter. It is equipped with a single RL10-B-2 engine, that also burns liquid hydrogen and liquid oxygen propellant and generates 25,000 pounds of thrust.

“The hardware for Exploration Flight Test-1 is coming together well,” Stowe noted in a NASA statement.

“We haven’t had to deal with any serious problems. All of the advance planning appears to be paying off.”

This same Delta IV upper stage will be used in the Block 1 version of NASA’s new heavy lift rocket, the Space Launch System (SLS).

Be sure to read my recent article detailing the ribbon cutting ceremony opening the manufacture of the SLS core stage at NASA’s Michoud Assembly Facility in New Orleans, LA. The SLS will be the most powerful rocket ever built by humans, exceeding that of the iconic Saturn V rocket that sent humans to walk on the surface of the Moon.

Wide view of the new welding tool at the Vertical Assembly Center at NASA’s Michoud Assembly Facility in New Orleans at a ribbon-cutting ceremony Sept. 12, 2014. Credit: Ken Kremer – kenkremer.com

The Delta IV rocket will be rolled out to the SLC-37 Cape Canaveral launch pad this week.
Assembly of the Orion EFT-1 capsule and stacking atop the service module was also completed in September at the Kennedy Space Center (KSC).

I was also on hand at KSC when the Orion crew module/service module (CM/SM) stack was rolled out on Sept. 11, 2014, on a 36-wheel transporter from its high bay assembly facility in the Neil Armstrong Operations and Checkout Building.

NASA’s completed Orion EFT 1 crew module loaded on wheeled transporter during move to Launch Abort System Facility (LASF) on Sept. 11, 2014 at the Kennedy Space Center, FL. Credit: Ken Kremer - kenkremer.com — NASA’s completed Orion EFT 1 crew module loaded on wheeled transporter during move to Launch Abort System Facility (LASF) on Sept. 11, 2014, at the Kennedy Space Center, FL. Credit: Ken Kremer – kenkremer.com

It was moved about 1 mile to its next stop on the way to SLC-37 – the KSC fueling facility named the Payload Hazardous Servicing Facility (PHFS). Read my Orion move story here.

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.

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

NASA’s Orion EFT 1 crew module departs Neil Armstrong Operation and Checkout Building on Sept. 11, 2014 at the Kennedy Space Center, FL, beginning the long journey to the launch pad and planned liftoff on Dec. 4, 2014. Credit: Ken Kremer - kenkremer.com — NASA’s Orion EFT 1 crew module departs Neil Armstrong Operation and Checkout Building on Sept. 11, 2014 at the Kennedy Space Center, FL, beginning the long journey to the launch pad and planned liftoff on Dec. 4, 2014. Credit: Ken Kremer – kenkremer.com

September 15, 2014December 23, 2015 by Ken Kremer

NASA Unveils World’s Largest Welder to Build World’s Most Powerful Rocket

MICHOUD ASSEMBLY FACILITY, NEW ORLEANS, LA – NASA Administrator Charles Bolden officially unveiled the world’s largest welder to start construction of the world’s most powerful rocket – NASA’s Space Launch System (SLS) rocket – at NASA’s Michoud Assembly Facility in New Orleans on Friday, Sept. 12, 2014.

Administrator Bolden was personally on hand for the ribbon-cutting ceremony at the base of the huge welder at Michoud’s Vertical Assembly Center (VAC).

The welder is now officially open for business and will be used to manufacture the core stage of the SLS, NASA’s mammoth heavy lift rocket that is intended to take humans to destinations far beyond Earth and farther into deep space than ever before possible – to Asteroids and Mars.

“The Road to Mars starts at Michoud,” said Bolden, at the welding tool ceremony attended by Universe Today.

The SLS is designed to launch astronaut crews aboard NASA’s next generation Orion deep space capsule concurrently under development.

The state-of-the-art welding giant stands 170 feet tall and 78 feet wide. It completes a world-class welding toolkit that will be used to assemble pieces of the SLS core stage including domes, rings and barrels that have already been manufactured. It will tower over 212 feet (64.6 meters) tall and sports a diameter of 27.6 feet (8.4 m).

The core stage stores cryogenic liquid hydrogen and liquid oxygen. Boeing is the prime contractor for the SLS core stage.

The SLS core stage builds on heritage from NASA’s Space Shuttle Program.

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.

As I reported recently, NASA managers formally approved the development of the agency’s mammoth Mars rocket after a thorough review of cost and engineering issues.

“The SLS Program continues to make significant progress,” said Todd May, SLS program manager.

“The core stage and boosters have both completed critical design review, and NASA recently approved the SLS Program’s progression from formulation to development. This is a major milestone for the program and proof the first new design for SLS is mature enough for production.”

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.

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.”

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

Ken Kremer

August 28, 2014December 23, 2015 by 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.

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

“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

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

August 9, 2014December 23, 2015 by Ken Kremer

Airframe Structure for First Commercial Dream Chaser Spacecraft Unveiled

SNC's Dream Chaser® orbital structural airframe at Lockheed Martin in Ft. Worth, Texas. Credit: Lockheed Martin

The orbital airframe structure for the first commercial Dream Chaser mini-shuttle that will launch to Earth orbit just over two years from now has been unveiled by Sierra Nevada Corporation (SNC) and program partner Lockheed Martin.

Sierra Nevada is moving forward with plans for Dream Chaser’s first launch and unmanned orbital test flight in November 2016 atop a United Launch Alliance (ULA) Atlas V rocket from Cape Canaveral, Florida.

The winged Dream Chaser is being developed under NASA’s Commercial Crew Program aimed at restoring America’s indigenous human spaceflight access to low Earth orbit and the International Space Station (ISS).

Dream Chaser commercial crew vehicle built by Sierra Nevada Corp docks at ISS

Lockheed Martin is fabricating the structural components for the Dream Chaser’s orbital spacecraft composite structure at the NASA’s Michoud Assembly Facility (MAF) in New Orleans, Louisiana.

MAF has played a long and illustrious history in human space flight dating back to Apollo and also as the site where all the External Tanks for NASA’s space shuttle program were manufactured. Lockheed Martin also builds the pressure vessels for NASA’s deep space Orion crew vehicle at MAF.

Each piece is thoroughly inspected to insure it meets specification and then shipped to Lockheed Martin’s Aeronautics facility in Fort Worth, Texas for integration into the airframe and co-bonded assembly.

Following helicopter release the private Dream Chaser spaceplane starts glide to runway at Edwards Air Force Base, Ca. during first free flight landing test on Oct. 26, 2013 - in this screenshot. Credit: Sierra Nevada Corp. — Following helicopter release the private Dream Chaser spaceplane starts glide to runway at Edwards Air Force Base, Ca. during first free flight landing test on Oct. 26, 2013 – in this screenshot. Credit: Sierra Nevada Corp.

Sierra Nevada chose Lockheed Martin for this significant role in building Dream Chaser airframe based on their wealth of aerospace experience and expertise.

The composite airframe structure was recently unveiled at a joint press conference by Sierra Nevada Corporation and Lockheed Martin at the Fort Worth facility.

“As a valued strategic partner on SNC’s Dream Chaser Dream Team, Lockheed Martin is under contract to manufacture Dream Chaser orbital structure airframes,” said Mark N. Sirangelo, corporate vice president of SNC’s Space Systems, in a statement.

“We competitively chose Lockheed Martin because they are a world leader in composite manufacturing, have the infrastructure, resources and quality control needed to support the needs of an orbital vehicle and have a proven track record of leading our nation’s top aviation and aerospace programs. Lockheed Martin’s diverse heritage coupled with their current work on the Orion program adds an extra element of depth and expertise to our program. SNC and Lockheed Martin continue to expand and develop a strong multi-faceted relationship.”

Dream Chaser measures about 29 feet long with a 23 foot wide wing span and is about one third the size of NASA’s space shuttle orbiters.

“We are able to tailor our best manufacturing processes, and our innovative technology from across the corporation to fit the needs of the Dream Chaser program,” said Jim Crocker, vice president of Lockheed Martin’s Space Systems Company Civil Space Line of Business.

Upon completion of the airframe manufacturing at Ft Worth, it will be transported to SNC’s Louisville, Colorado, facility for final integration and assembly.

Lockheed Martin will also process Dream Chaser between orbital flights at the Kennedy Space Center, FL in the recently renamed Neil Armstrong Operations and Checkout Building.

SNC announced in July that they successfully completed and passed a series of risk reduction milestone tests on key flight hardware systems under its Commercial Crew Integrated Capability (CCiCap) agreement with NASA that move the private reusable spacecraft closer to its critical design review (CDR) and first flight.

As a result of completing Milestones 9 and 9a, SNC has now received 92% of its total CCiCAP Phase 1 NASA award of $227.5 million.

“We are on schedule to launch our first orbital flight in November of 2016, which will mark the beginning of the restoration of U.S. crew capability to low-Earth orbit,” says Sirangelo.

The private Dream Chaser is a reusable lifting-body design spaceship that will carry a mix of cargo and up to a seven crewmembers to the ISS. It will also be able to land on commercial runways anywhere in the world, according to SNC.

Dream Chaser is among a trio of US private sector manned spaceships being developed with seed money from NASA’s Commercial Crew Program in a public/private partnership to develop a next-generation crew transportation vehicle to ferry astronauts to and from the International Space Station by 2017 – a capability totally lost following the space shuttle’s forced retirement in 2011.

The SpaceX Dragon and Boeing CST-100 ‘space taxis’ are also vying for funding in the next round of contracts to be awarded by NASA around September 2014, NASA officials have told me.

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

Ken Kremer

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

March 21, 2012April 13, 2022 by Ken Kremer

Orion Crew Capsule Targeted for 2014 Leap to High Orbit

The Orion Exploration Flight Test-1 (EFT-1) is scheduled to launch the first unmanned Orion crew cabin into a high altitude Earth orbit in 2014 atop a Delta 4 Heavy rocket from Cape Canaveral, Florida. Artist’s concept. Credit: NASA

[/caption]

NASA is on course to make the highest leap in human spaceflight in nearly 4 decades when an unmanned Orion crew capsule blasts off from Cape Canaveral, Fla., on a high stakes, high altitude test flight in early 2014.

A new narrated animation (see below) released by NASA depicts the planned 2014 launch of the Orion spacecraft on the Exploration Flight Test-1 (EFT-1) mission to the highest altitude orbit reached by a spaceship intended for humans since the Apollo Moon landing Era.

Orion is NASA’s next generation human rated spacecraft and designed for missions to again take humans to destinations beyond low Earth orbit- to the Moon, Mars, Asteroids and Beyond to deep space.

Orion Video Caption – Orion: Exploration Flight Test-1 Animation (with narration by Jay Estes). This animation depicts the proposed test flight of the Orion spacecraft in 2014. Narration by Jay Estes, Deputy for flight test integration in the Orion program.

Lockheed Martin Space Systems is making steady progress constructing the Orion crew cabin that will launch atop a Delta 4 Heavy booster rocket on a two orbit test flight to an altitude of more than 3,600 miles and test the majority of Orion’s vital vehicle systems.

The capsule will then separate from the upper stage, re-enter Earth’s atmosphere at a speed exceeding 20,000 MPH, deploy a trio of huge parachutes and splashdown in the Pacific Ocean off the west coast of California.

Lockheed Martin is responsible for conducting the critical EFT-1 flight under contract to NASA.

Orion will reach an altitude 15 times higher than the International Space Station (ISS) circling in low orbit some 250 miles above Earth and provide highly valuable in-flight engineering data that will be crucial for continued development of the spaceship.

Orion Exploration Flight Test One Overview. Credit: NASA

“This flight test is a challenge. It will be difficult. We have a lot of confidence in our design, but we are certain that we will find out things we do not know,” said NASA’s Orion Program Manager Mark Geyer.

“Having the opportunity to do that early in our development is invaluable, because it will allow us to make adjustments now and address them much more efficiently than if we find changes are needed later. Our measure of success for this test will be in how we apply all of those lessons as we move forward.”

Lockheed Martin is nearing completion of the initial assembly of the Orion EFT-1 capsule at NASA’s historic Michoud Assembly Facility (MAF) in New Orleans, which for three decades built all of the huge External Fuel Tanks for the NASA’s Space Shuttle program.

In May, the Orion will be shipped to the Kennedy Space Center in Florida for final assembly and eventual integration atop the Delta 4 Heavy rocket booster and launch from Space Launch Complex 37 at nearby Cape Canaveral. The Delta 4 is built by United Launch Alliance.

The first integrated launch of an uncrewed Orion is scheduled for 2017 on the first flight of NASA’s new heavy lift rocket, the SLS or Space Launch System that will replace the now retired Space Shuttle orbiters

Continued progress on Orion, the SLS and all other NASA programs – manned and unmanned – is fully dependent on the funding level of NASA’s budget which has been significantly slashed by political leaders of both parties in Washington, DC in recent years.

…….

March 24 (Sat): Free Lecture by Ken Kremer at the New Jersey Astronomical Association, Voorhees State Park, NJ at 830 PM. Topic: Atlantis, the End of Americas Shuttle Program, Orion, SpaceX, CST-100 and the Future of NASA Human & Robotic Spaceflight