Heat Shield for 2014 Orion Test Flight Arrives at Kennedy Aboard NASA’s Super Guppy

Orion EFT-1 heat shield is off loaded from NASA’s Super Guppy aircraft after transport from Manchester, N.H., and arrival at the Kennedy Space Center in Florida on Dec. 5, 2013. Credit: Ken Kremer/kenkremer.com

Orion EFT-1 heat shield is off loaded from NASA’s Super Guppy aircraft after transport from Manchester, N.H., and arrival at the Kennedy Space Center in Florida on Dec. 5, 2013. Credit: Ken Kremer/kenkremer.com
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KENNEDY SPACE CENTER, FL – The heat shield crucial to the success of NASA’s 2014 Orion test flight has arrived at the Kennedy Space Center (KSC) aboard the agency’s Super Guppy aircraft – just spacious enough to fit the precious cargo inside.

Orion is currently under development as NASA’s next generation human rated vehicle to replace the now retired space shuttle. The heat shields advent is a key achievement on the path to the spacecraft’s maiden flight.

“The heat shield which we received today marks a major milestone for Orion. It is key to the continued assembly of the spacecraft,” Scott Wilson, NASA’s Orion Manager of Production Operations at KSC, told Universe Today during an interview at the KSC shuttle landing facility while the offloading was in progress.

“It will be installed onto the bottom of the Orion crew module in March 2014.”

The inaugural flight of Orion on the unmanned Exploration Flight Test – 1 (EFT-1) mission is scheduled to blast off from the Florida Space Coast in mid September 2014 atop a Delta 4 Heavy booster, Wilson told me.

Orion EFT-1 heat shield moved off from NASA’s Super Guppy aircraft after arrival at the Kennedy Space Center in Florida on Dec. 5, 2013. Credit: Ken Kremer/kenkremer.com
Orion EFT-1 heat shield moved off from NASA’s Super Guppy aircraft after arrival at the Kennedy Space Center in Florida on Dec. 5, 2013. Credit: Ken Kremer/kenkremer.com

The heat shield was flown in from Textron Defense Systems located near Boston, Massachusetts and offloaded from the Super Guppy on Dec. 5 as Universe Today observed the proceedings along with top managers from NASA and Orion’s prime contractor Lockheed Martin.

“The Orion heat shield is the largest of its kind ever built. Its wider than the Apollo and Mars Science Laboratory heat shields,” Todd Sullivan told Universe Today at KSC. Sullivan is the heat shield senior manager at Lockheed Martin.

The state-of-the-art Orion crew capsule will ultimately enable astronauts to fly to deep space destinations including the Moon, Asteroids, Mars and beyond – throughout our solar system.

The heat shield was one of the last major pieces of hardware needed to complete Orion’s exterior structure.

“Production of the heat shields primary structure that carries all the loads began at Lockheed Martin’s Waterton Facility near Denver,” said Sullivan. The titanium composite skeleton and carbon fiber skin were manufactured there to give the heat shield its shape and provide structural support during landing.

“It was then shipped to Textron in Boston in March,” for the next stage of assembly operations, Sullivan told me.

“They applied the Avcoat ablater material to the outside. That’s what protects the spacecraft from the heat of reentry.”

Textron technicians just completed the final work of installing a fiberglass-phenolic honeycomb structure onto the heat shield skin. Then they filled each of the honeycomb’s 320,000 cells with the ablative material Avcoat.

Orion EFT-1 heat shield hauled off NASA’s Super Guppy aircraft after arrival at the Kennedy Space Center in Florida on Dec. 5, 2013. Credit: Ken Kremer/kenkremer.com
Orion EFT-1 heat shield hauled off NASA’s Super Guppy aircraft after arrival at the Kennedy Space Center in Florida on Dec. 5, 2013. Credit: Ken Kremer/kenkremer.com

Each cell was X-rayed and sanded to match Orion’s exacting design specifications.

“Now we have about two and a half months of work ahead to prepare the Orion crew module before the heat shield is bolted on and installed,” Sullivan explained.

The Avcoat-treated shell will shield Orion from the extreme heat of nearly 4000 degrees Fahrenheit it experiences during the blazing hot temperatures it experiences as it returns at high speed to Earth. The ablative material will wear away as it heats up during the capsules atmospheric re-entry thereby preventing heat from being transferred to the rest of the capsule and saving it and the human crew from utter destruction.

“Testing the heat shield is one of the prime objectives of the EFT-1 flight,” Wilson explained.

“The Orion EFT-1 capsule will return at over 20,000 MPH,” Wilson told me. “That’s about 80% of the reentry speed experienced by the Apollo capsule after returning from the Apollo moon landing missions.”

“The big reason to get to those high speeds during EFT-1 is to be able to test out the thermal protection system, and the heat shield is the biggest part of that.”

Hoisting Orion heat shield at KSC for transport to Orion crew module in the Operations and Checkout Building. Credit: Ken Kremer/kenkremer.com
Hoisting Orion heat shield at KSC for transport to Orion crew module in the Operations and Checkout Building. Credit: Ken Kremer/kenkremer.com

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.

“Numerous sensors and instrumentation have been specially installed on the EFT-1 heat shield and the back shell tiles to collect measurements of things like temperatures, pressures and stresses during the extreme conditions of atmospheric reentry,” Wilson explained.

Orion managers pose with heat shield at KSC; Scott Wilson, NASA Orion deputy manager of Production Operations; Todd Sullivan, heat shield senior manager at Lockheed Martin; Stu Mcclung, NASA Orion deputy manager of Production Operations. Credit: Ken Kremer/kenkremer.com
Orion managers pose with heat shield at KSC; Scott Wilson, NASA Orion deputy manager of Production Operations; Todd Sullivan, heat shield senior manager at Lockheed Martin; Stu Mcclung, NASA Orion deputy manager of Production Operations. Credit: Ken Kremer/kenkremer.com

The data gathered during the unmanned EFT-1 flight will aid in confirming. or refuting, design decisions and computer models as the program moves forward to the first flight atop NASA’s mammoth SLS booster in 2017 on the EM-1 mission and human crewed missions thereafter.

“I’m very proud of the work we’ve done, excited to have the heat shield here [at KSC] and anxious to get it installed,” Sullivan concluded.

Stay tuned here for continuing Orion, Chang’e 3, LADEE, MAVEN and MOM news and Ken’s reports from on site at Cape Canaveral & the Kennedy Space Center press site.

Ken Kremer

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Learn more about Orion, MAVEN, MOM, Mars rovers, Chang’e 3, SpaceX, and more at Ken’s upcoming presentations

Dec 10: “Antares ISS Launch from Virginia, Mars and SpaceX Mission Update”, Amateur Astronomers Association of Princeton, Princeton University, Princeton, NJ, 8 PM

Dec 11: “Curiosity, MAVEN and the Search for Life on Mars”, “LADEE & Antares ISS Launches from Virginia”, Rittenhouse Astronomical Society, Franklin Institute, Phila, PA, 8 PM

Departure of NASA’s Super Guppy from the shuttle landing runway at the Kennedy Space Center in Florida on Dec. 5, 2013 after removal of Orion heat shield.  Credit: Ken Kremer/kenkremer.com
Takeoff of NASA’s Super Guppy from the shuttle landing runway at the Kennedy Space Center in Florida on Dec. 5, 2013 after removal of Orion heat shield. Credit: Ken Kremer/kenkremer.com

Orion Service Module Comes Together and Testing Affirms Flight Design for 2014 Blastoff

Inside the Operations and Checkout Building high bay at NASA’s Kennedy Space Center in Florida, a crane moves the service module for the Orion spacecraft toward a lift station where it will be mated to the spacecraft adapter cone. Photo credit: NASA/Jim Grossmann

KENNEDY SPACE CENTER, FL – All of the key hardware elements being assembled for NASA’s new Orion spacecraft launching just under one year from now are nearing completion at the Kennedy Space Center (KSC) – at the same time as a crucial and successful hardware test in California this week helps ensure that the Exploration Flight Test-1 (EFT-1) vehicle will be ready for an on-time liftoff.

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.

In a major construction milestone, Orion’s massive Service Module (SM) was hoisted out from the tooling stand where it was manufactured at the Operations and Checkout Building (O & C) at KSC and moved to the next assembly station where it will soon be mated to the spacecraft adapter cone.

The SM should be mated to the crew module (CM) by year’s end, Orion managers told Universe Today during my recent inspection tour of significant Orion hardware at KSC.

“We are working 24 hours a day, 7 days a week,” said Jules Schneider, Orion Project manager for Lockheed Martin at KSC, during an exclusive interview with Universe Today inside the Orion clean room at KSC. “We are moving fast!”

The three panel or fairings encapsulating a stand-in for Orion’s service module successfully detach during a test Nov. 6, 2013 at Lockheed Martin’s facility in Sunnyvale, Calif. Image Credit: Lockheed Martin
The three panels or fairings encapsulating a stand-in for Orion’s service module successfully detach during a test Nov. 6, 2013 at Lockheed Martin’s facility in Sunnyvale, Calif. Image Credit: Lockheed Martin

The Orion CM recently passed a significant milestone when it was “powered on” for the first time at KSC.

“We are bringing Orion to life. Lots of flight hardware has now been installed.”

And on the other side of the country, the Service Module design passed a key hurdle on Wednesday (Nov. 6) when the trio of large spacecraft panels that surround the SM were successfully jettisoned from the spacecraft during a systems test by Lockheed Martin that simulates what would happen during an actual flight several minutes after liftoff.

“Hardware separation events like this are absolutely critical to the mission and some of the more complicated things we do,” said Mark Geyer, Orion program manager at NASA’s Johnson Space Center in Houston. “We want to know we’ve got the design exactly right and that it can be counted on in space before we ever launch.”

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.  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) mock up 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

Lockheed Martin is the prime contractor for Orion and responsible for assembly, testing and delivery of the Orion EFT-1 spacecraft to NASA that’s slated for an unmanned test flight targeted to lift off from Cape Canaveral, Florida in September 2014.

The CM rests atop the SM similar to the Apollo Moon landing program architecture.

However in a significant difference from Apollo, the Orion fairings 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 thus maximizing the vehicles size and capability.

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

At Lockheed Martin’s Sunnyvale, California facility a team of engineers used a series of precisely-timed, explosive charges and mechanisms attached to the Orion’s protective fairing panels in a flight-like test to verify that the spacecraft can successfully and confidently jettison them as required during the ascent to orbit.

The trio of fairing panels protect the SM radiators and solar arrays from heat, wind and acoustics during ascent.

The three panels or fairings encapsulating a stand-in for Orion’s service module successfully detach during a test Nov. 6, 2013 at Lockheed Martin’s facility in Sunnyvale, Calif. Image Credit: Lockheed Martin
The three panels or fairings encapsulating a stand-in for Orion’s service module successfully detach during a test Nov. 6, 2013 at Lockheed Martin’s facility in Sunnyvale, Calif. Image Credit: Lockheed Martin

“This successful test provides the Orion team with the needed data to certify this new fairing design for Exploration Flight Test-1 (EFT-1) next year. The test also provides significant risk reduction for the fairing separation on future Orion manned missions,” said Lance Lininger, engineering lead for Lockheed Martin’s Orion mechanism systems in a statement.

This was the 2nd test of the fairing jettison system. During the first test in June, one of the three fairing panels did not completely detach due to an interference “when the top edge of the fairing came into contact with the adapter ring and kept it from rotating away and releasing from the spacecraft,” said NASA.

Inside the Operations and Checkout Building high bay at NASA’s Kennedy Space Center in Florida, a crane moves the service module for the Orion spacecraft toward a lift station where it will be mated to the spacecraft adapter cone. Photo credit: NASA/Jim Grossmann
Inside the Operations and Checkout Building high bay at NASA’s Kennedy Space Center in Florida, a crane moves the service module for the Orion spacecraft toward a lift station where it will be mated to the spacecraft adapter cone. Photo credit: NASA/Jim Grossmann

2013 has been an extremely busy and productive year for the Orion EFT-1 team.

“There are many significant Orion assembly events ongoing this year,” said Larry Price, Orion deputy program manager at Lockheed Martin, in an interview with Universe Today at Lockheed 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, building the service module and finally mating the crew and service modules (CM & SM),” Price told me.

Technicians work inside the Orion crew module being built at Kennedy Space Center to prepare it for its first power on. Turning the avionics system inside the capsule on for the first time marks a major milestone in Orion’s final year of preparations before its first mission, Exploration Flight Test 1 Credit: Lockheed Martin
Technicians work inside the Orion crew module being built at Kennedy Space Center to prepare it for its first power on. Turning the avionics system inside the capsule on for the first time marks a major milestone in Orion’s final year of preparations before its first mission, Exploration Flight Test 1
Credit: Lockheed Martin

The two-orbit, four- hour 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.

Ken Kremer

The Stars of Orion Seen Blazing From Orbit

The constellation Orion photographed from orbit by Karen Nyberg (NASA)

The mighty hunter soars above the atmosphere in this photo, taken by NASA astronaut Karen Nyberg currently living and working in space aboard the ISS. One of the most recognizable constellations in night skies all across the Earth, Orion also puts on an impressive display for those well above the Earth!


Appearing here to be lying on his right side, the three stars of Orion’s famous belt — Mintaka, Alnilam, and Alnitak, top to bottom — are center frame, while his sword is nearly horizontal just to the right (the blurry center star of which isn’t a star at all, of course, but rather the enormous star-forming Orion nebula.)

Betelgeuse, as seen by the Hubble Space Telescope.
Betelgeuse, as seen by the Hubble Space Telescope.

At Orion’s right shoulder is Betelgeuse, a huge red giant 20 times more massive than our Sun. Its fiery color is obvious in Karen’s photo, mirroring many of the much-closer human-made city lights visible on the ground.

In addition to featuring my favorite constellation, this photo that Karen recently shared on Twitter also serves to prove (to those few who still require evidence of such) that yes, astronauts can see stars from space. Very nicely too, I may add. The only reason they are not visible in all images is purely photographic — cameras exposing for a bright scene, like a daylit Earth (or Moon) won’t be able to capture the relatively much dimmer light of stars in the same shot, making it look like space is empty of them. Even here we can see a bit of noise in the glowing line of Earth’s atmosphere and a little blurring of edges — that’s a result of a high ISO setting to increase camera sensitivity along with a slightly longer shutter speed than your hand can easily keep stable… again, all to better capture the faint streams of photons from distant stars.

Blaze on, mighty Hunter! See this and more views from the ISS on Karen’s Twitter page here.

Orion Crew Module Comes Alive at T Minus 1 Year to Maiden Blastoff

Technicians work inside the Orion crew module being built at Kennedy Space Center to prepare it for its first power on. Turning the avionics system inside the capsule on for the first time marks a major milestone in Orion’s final year of preparations before its first mission, Exploration Flight Test 1 Credit: Lockheed Martin

Technicians work inside the Orion crew module being built at Kennedy Space Center to prepare it for its first power on. Turning the avionics system inside the capsule on for the first time marks a major milestone in Orion’s final year of preparations before its first mission, Exploration Flight Test 1. Credit: Lockheed Martin
Story and imagery updated[/caption]

KENNEDY SPACE CENTER, FL – Orion, the first NASA spaceship that will ever carry Earthlings to deep space destinations, has at last been “powered on” for the first time at the manufacturing facility at the Kennedy Space Center (KSC) where it’s the centerpiece of a beehive humming 24/7 with hi tech processing activities in all directions.

“Power On” marks a major milestone ahead of the maiden space bound Orion test flight dubbed “EFT-1” – now at T-Minus 1 year and counting!

NASA and prime contractor Lockheed Martin recently granted Universe Today an exclusive in depth inspection tour of the impressive Orion EFT-1 crew module, service module and associated hardware destined for the crucial unmanned test flight slated for liftoff from Cape Canaveral in September 2014.

“We are moving fast!” said Jules Schneider, Orion Project manager for Lockheed Martin at KSC, during an exclusive interview with Universe Today as we spoke beside the Orion EFT-1 spacecraft inside the clean room.

“We are bringing Orion to life. Lots of flight hardware has now been installed.”

Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) mock ups stacked 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) mock up 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

“We are working 24 hours a day, 7 days a week,” Schneider told me.

Some 200 people are actively employed on building Orion by Lockheed Martin at the Kennedy Space Center.

“There are many significant Orion assembly events ongoing this year,” said Larry Price, Orion deputy program manager at Lockheed Martin, in an interview with Universe Today at Lockheed 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, building the service module and finally mating the crew and service modules (CM & SM),” Price told me.

Orion is a state of the art crew capsule that will ultimately enable astronauts to fly to deep space destinations including the Moon, Asteroids, Mars and beyond – throughout our solar system.

And Universe Today has had a front row seat.

I have been very fortunate to periodically visit Orion up close over the past year and half to evaluate the testing and assembly progress inside the Operations and Checkout Building at KSC where the vehicle is now rapidly coming together, since the bare bones pressure vessel arrived to great fanfare in June 2012.

For the first time Orion looked to my eyes like a real spaceship, rather than the backbone shell outfitted with hundreds of important test harnesses, strain gauges and wiring to evaluate its physical and structural integrity.

Technicians work inside the Orion crew module being built at Kennedy Space Center to prepare it for its first power on. Turning the avionics system inside the capsule on for the first time marks a major milestone in Orion’s final year of preparations before its first mission, Exploration Flight Test 1 Credit: Lockheed Martin
Technicians work inside the Orion crew module being built at Kennedy Space Center to prepare it for its first power on. Turning the avionics system inside the capsule on for the first time marks a major milestone in Orion’s final year of preparations before its first mission, Exploration Flight Test 1. Credit: Lockheed Martin

Engineers and technicians at KSC have removed the initial pressure testing gear and are now installing all the flight systems and equipment – such as avionics, instrumentation, flight computers, thrusters, wiring, plumbing, heat shield and much more – required to transform the initial empty shell into a fully functioning spacecraft.

“The Orion skeleton was here before. Now we are putting in all of the other systems,” Schneider explained to me.

“We are really busy.”

“So far over 66,000 Orion parts have been shipped to KSC from over 40 US states,” Price explained.

The heat shield was due to arrive soon and technicians were drilling its attachment ring holes as I observed the work in progress.

“The propulsion, environmental control and life support systems are now about 90% in. The ammonia and propylene glycol loops for the thermal control system are in. Many of the flight harnesses are installed.”

“All of the reaction control thrusters are in – fueled by hydrazine – as well as the two hydrazine tanks and a helium tank. Altogether there are 12 hydrazine pods with two thrusters each,” Schneider elaborated.

The power distribution unit (PDU) – which basically functions as Orion’s computer brains – was installed just prior to my visit. All four PDU’s – which issue commands to the vehicle – were built by Honeywell.

Technicians were actively installing fiber optic and coaxial cables as I watched. They also were conducting leak tests on the environmental control coolant (ECLS) systems which had to be completed before the ‘power on’ testing could begin – in order to cool the avionics systems.

Thermal protection system (TPS) tiles were being bonded to the back panels which ring Orion. The TPS panels get attached early in 2014.

“This is real stuff,” said Schneider gleefully.

Inside the Operations and Checkout Building high bay at NASA’s Kennedy Space Center in Florida, a tile technician works on a section of thermal protection system tiles seen by Universe Today  and that will be installed on the Orion crew module. Credit: NASA/Dimitri Gerondidakis
Inside the Operations and Checkout Building high bay at NASA’s Kennedy Space Center in Florida, a tile technician works on a section of thermal protection system tiles seen by Universe Today and that will be installed on the Orion crew module. Credit: NASA/Dimitri Gerondidakis

NASA says that “the preliminary data indicate Orion’s vehicle management computer, as well as its innovative power and data distribution system — which use state-of-the-art networking capabilities — performed as expected” during the initial crew module power on.

About two months or so of power on functional testing of various systems will follow.

Just like the configuration used in the Apollo era, the Orion crew module will sit atop a service module – and that work is likewise moving along at a rapid clip.

“The Orion service module (SM) is also almost complete,” Schneider said as he showed me the service module structure.

“Structurally the SM is 90% done. The active thermal control system is in and all the fluid systems are welded in and pressure tested.”

Cutaway diagram of Orion components including crew module and service module and adapters. Credit: NASA
Cutaway diagram of Orion components including crew module and service module and adapters. Credit: NASA

Orion EFT-1 will blastoff atop a mammoth United Launch Alliance Delta IV Heavy rocket – the most powerful booster in America’s arsenal since the shuttle’s retirement in 2011.

The crew module and service module (CM/SM) will be mated inside the O&C and then be placed onto a mission adapter that eventually attaches to the top of the Delta IV Heavy booster.

They will be mated at the exact same spot in the O&C Building where the Apollo era command and service modules were stacked four decades ago.

Currently, the schedule calls for the Orion CM/SM stack to roll out to Kennedy’s Payload Hazardous Services Facility (PHSF) for servicing and fueling late this year, said Larry Price.

After that the CM/SM stack is transported to the nearby Launch Abort System Facility (LASF) for mating to the emergency Launch Abort System (LAS).

All that work could be done around March 2014 so that ground operations preparing for launch can commence, according to Price.

“In March 2014 we’ll be ready for ground ops. The normal launch processing flow starts in June 2014 leading to Orion’s launch from pad 37 in September 2014.”

“It’s very exciting and a tribute to the NASA and contractor teams,” Price said.

The 2014 uncrewed flight will be loaded with a wide variety of instruments to evaluate how the spacecraft behaves during launch, in space and then through the searing heat of reentry.

The two-orbit, four- hour 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.

An artist concept shows Orion as it will appear in space for the Exploration Flight Test-1 attached to a Delta IV second stage.   Credit: NASA
An artist concept shows Orion as it will appear in space for the Exploration Flight Test-1 attached to a Delta IV second stage. Credit: NASA

Although the mission will only last a few hours it will be high enough to send the vehicle plunging back into the atmosphere and a Pacific Ocean splashdown to test the craft and its heat shield at deep-space reentry speeds of 20,000 mph and endure temperatures of 4,000 degrees Fahrenheit – like those of the Apollo moon landing missions.

The Orion EFT-1 mission will end with a splashdown in the Pacific Ocean. During the stationary recovery test of Orion at Norfolk Naval Base on Aug. 15, 2013, US Navy divers attached tow lines and led the test capsule to a flooded well deck on the USS Arlington. Credit: Ken Kremer/kenkremer.com.
The Orion EFT-1 mission will end with a splashdown in the Pacific Ocean. During the stationary recovery test of Orion at Norfolk Naval Base on Aug. 15, 2013, US Navy divers attached tow lines and led the test capsule to a flooded well deck on the USS Arlington. Credit: Ken Kremer/kenkremer.com.

The EFT-1 mission will provide engineers with critical data about Orion’s heat shield, flight systems and capabilities to validate designs of the spacecraft, inform design decisions, validate existing computer models and guide new approaches to space systems development. All these measurements will aid in reducing the risks and costs of subsequent Orion flights before it begins carrying humans to new destinations in the solar system.

“The Orion hardware and the Delta IV Heavy booster for the EFT-1 launch are on target for launch in 2014,” Scott Wilson, NASA’s Orion Manager of Production Operations, told Universe Today in an interview.

Ken Kremer

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Learn more about Orion, MAVEN, Mars rovers and more at Ken’s upcoming presentations

Nov 14-19: “MAVEN Mars Launch and Curiosity Explores Mars, Orion and NASA’s Future”, Kennedy Space Center Quality Inn, Titusville, FL, 8 PM

Dec 11: “Curiosity, MAVEN and the Search for Life on Mars”, “LADEE & Antares ISS Launches from Virginia”, Rittenhouse Astronomical Society, Franklin Institute, Phila, PA, 8 PM

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

New Comet Discovered: Lovejoy Will Add to “Comet Lineup” in Winter Skies

New Comet Lovejoy starts out slow but quickly gains speed as it crosses from near Orion in mid-September to Ursa Major in November, when it will be closest to Earth. Created with Chris Marriott's SkyMap software

Move over Comet ISON. You’ve got company.  Australian amateur astronomer Terry Lovejoy, discoverer of three previous comets, including the famous, long-tailed sungrazer C/2011 W3 (Lovejoy), just added a 4th to his tally.

This new comet will add to a lineup of comets that should grace early November skies in the northern hemisphere: Comets ISON, Encke and now the new Lovejoy.

Comet C/2013 R1 Lovejoy photographed on Sept. 10. The comet is visible in larger amateur telescopes in September but may brighten to small scope visibility in November. Credit: Michael Jaeger
Comet C/2013 R1 Lovejoy photographed on Sept. 10. The comet is visible in larger amateur telescopes in September but may brighten to small scope visibility in November. Streak at right is a geostationary satellite. Credit: Michael Jaeger

The discovery of C/2013 R1 Lovejoy was announced on Sept. 9 after two nights of photographic observations by Lovejoy with an 8-inch (20 cm) Schmidt-Cassegrain reflector. When nabbed, the comet was a faint midge of about 14.5 magnitude crossing the border between Orion and Monoceros. Subsequent observations by other amateur astronomers peg it a bit brighter at 14.0 with a small, condensed coma.

Comet Lovejoy has a small, condensed coma (head) about 30 arc seconds across with a faint, short tail in this photo made on Sept. 8. Credit: Ernesto Guido and Nick Howes
Comet Lovejoy has a small, condensed coma (head) about 30 arc seconds across with a faint, short tail in this photo made on Sept. 8. Credit: Ernesto Guido and Nick Howes

Right now you’ll need a hefty telescope to catch a glimpse of Lovejoy’s latest, but come November the comet will glow at around 8th magnitude, making it a perfect target for smaller telescopes. At closest approach on the Nov. 23, Lovejoy will pass 38.1 million miles (61.3 million km) from Earth while sailing across the Big Dipper at a quick pace.

The comet is a faint 14th magnitude object just east of Orion's Belt in the dim constellation Monoceros the Unicorn. The map shows its position tomorrow morning Sept. 11 just before the  start of morning twilight. Stellarium
The comet is a faint 14th magnitude object just east of Orion’s Belt in the dim constellation Monoceros the Unicorn. The map shows its position tomorrow morning Sept. 11 just before the start of morning twilight. Stellarium

Mid to late November is also the time when Comet ISON, the current focus of much professional and amateur observation, will be at its brightest in the morning sky at around magnitude 2-3. Get ready for some busy nights at the telescope!

A graph showing the comet's predicted magnitude (subject to change) in red versus the comet's elongation or distance from the sun. You can see that it will up in a dark sky for a long time especially around the time when it's brightest. Credit: Ernesto Guido & Nick Howes
A graph showing the comet’s predicted magnitude (subject to change) in red versus the comet’s elongation or angular distance from the sun. You can see that it will up in a dark sky for a long time including around the time when it’s brightest. Credit: Ernesto Guido & Nick Howes

C/2013 R1 will whip by the sun on Christmas Day at a distance of 81 million miles (130.3 million km) and then return back to the deeps from whence it came.

The charts here give you a general idea of its location and path over the next couple months. As the comet crosses into small-scope territory in early November, I’ll provide maps for you to find it.

A graphic created by Stuart Atkinson showing the comet and planetary lineup that should be in the skies on November 9, 2013.
A graphic created by Stuart Atkinson showing the comet and planetary lineup that should be in the skies on November 9, 2013.

And as Stuart Atkinson noted on his website, Cumbrian Sky a great lineup should be in the northern hemisphere skies on November 9, 2013. From the left, Comet Encke will be magnitude 6, ISON should be at about magnitude 6 or 7; then Mars, followed by the new Comet Lovejoy, which will be still very faint at around magnitude 9, topped off by a bright Jupiter. The comets will not likely be of naked eye visibility, but this should be a great chance for astrophotographer to capture this lineup!

Comet Lovejoy is approaching the plane of the planets from down under. The diagram shows the comet's position today. Like many comets, Lovejoy's orbit is steeply inclined - in this case 62 degrees. Credit: NASA
Comet Lovejoy is approaching the plane of the planets from “down under” (lower right). The diagram shows the comet’s position today. Like many comets, Lovejoy’s orbit is steeply inclined – in this case 62 degrees. Credit: NASA

Welcome to an exciting time for comet lovers, and congratulations Terry on another great discovery!

Astrophoto: Flaming Star and Nebula in Orion

The star Alnitak and Flame Nebula in Orion. Credit and copyright: César Cantú.

Astrophotographer César Cantú from Mexico captured this beautiful view of the star Alnitak and Flame Nebula, both in the constellation Orion. Alnitak is the southern star in Orion’s belt, and is an extremely hot star, with a temperature of 29,500 ± 1000 K. It shines brilliantly, and is about 10,000 times more luminous than the Sun. This star also makes the Flame Nebula appear to be blazing, too. Wind and radiation from Alnitak blasts away electrons from the gas in the Flame nebula, causing it to become ionized and glow in visible light.

This gorgeous view was captured on August 11, 2013.

Want to get your astrophoto featured on Universe Today? Join our Flickr group or send us your images by email (this means you’re giving us permission to post them). Please explain what’s in the picture, when you took it, the equipment you used, etc.

NASA & US Navy Test Demonstrates Water Recovery of Orion Crew Capsule

During the stationary recovery test of Orion at Norfolk Naval Base on Aug. 15, US Navy divers attached tow lines and led the test capsule to a flooded well deck on the USS Arlington. Credit: Ken Kremer/kenkremer.com

During the stationary recovery test of Orion at Norfolk Naval Base on Aug. 15, 2013, US Navy divers attached tow lines and led the test capsule to a flooded well deck on the USS Arlington. Credit: Ken Kremer/kenkremer.com.
Story updated with additional test Video and images[/caption]

NAVAL STATION NORFOLK,VA – When American astronauts again venture into deep space sometime in the next decade, their return trip to Mother Earth will end with the splashdown of their Orion capsule in the Pacific Ocean – much like the Apollo lunar landing crews of four decades ago.

But before that can happen, Orion must first pass through a myriad of milestones to insure the safe return of our human crews.

A NASA and U.S. Navy test successfully demonstrated the water recovery of the Orion crew module today (Aug. 15) at Naval Station Norfolk in Virginia – and Universe Today witnessed the entire operation.

“Today’s test was terrific,” Scott Wilson, NASA’s Orion Manager of Production Operations, told Universe Today in a post test interview at Naval Station Norfolk.

“We got all the data we needed and the test was very successful. This was exactly what we wanted to do and we don’t like surprises.”

US Navy divers on four boats attached tow lines and to the Orion test capsule and guide it to the well deck on the USS Arlington during Aug. 15 recovery test Norfolk Naval Base, VA.  Credit: Ken Kremer/kenkremer.com
US Navy divers on four boats attached tow lines and to the Orion test capsule and guide it to the well deck on the USS Arlington during Aug. 15 recovery test at Norfolk Naval Base, VA.

Credit: Ken Kremer/kenkremer.com

Today’s ‘Orion Stationary Recovery Test’ was conducted to support the upcoming first flight of Orion on the EFT-1 mission due to blastoff in September 2014 from Cape Canaveral, Florida.

“We completed all of our primary and secondary test objectives,” Wilson stated.

Teams of US Navy divers in a flotilla of amphibious boats launched from the USS Arlington approached a test version of the Orion capsule known as the boilerplate test article (BTA). The Arlington was docked against its pier during the test in a benign, controlled environment.

Dive teams attach tow lines to Orion test capsule during Aug. 15 recovery test at Norfolk Naval Base, VA.  Credit: Ken Kremer/kenkremer.com
Dive teams attach tow lines to Orion test capsule during Aug. 15 recovery test at Norfolk Naval Base, VA. Credit: Ken Kremer/kenkremer.com

Divers attached several tow lines to the capsule, in a coordinated operation with the Arlington, and led the capsule into the ship’s flooded well deck.

The Orion capsule was carefully towed inside the well deck and positioned over the recovery cradle. The sea water was drained and the capsule was attached to the recovery cradle.

Dive teams haul Orion onto the well deck of the USS Arlington during Aug. 15 recovery test at Norfolk Naval Base, VA.  Credit: Ken Kremer/kenkremer.com
Dive teams haul Orion onto the well deck of the USS Arlington during Aug. 15 recovery test at Norfolk Naval Base, VA. Credit: Ken Kremer/kenkremer.com

“During the test there is constant radio communications between the ship and the divers teams in the boats.”

“The operation within the well deck areas are also being controlled as well as the rope and winch handlers on the boat,” Wilson told me.

At the conclusion of the test, myself and the NASA social media participants boarded the USS Arlington and toured the Orion capsule for a thrilling up close look.

Myself and NASA social media participate observed Orion after hauled aboard the well deck and boarded the USS Arlington recovery ship.    Credit: Ken Kremer/kenkremer.com
Myself and NASA social media participants observed Orion after hauled aboard the well deck and boarded the USS Arlington recovery ship. Credit: Ken Kremer/kenkremer.com

“Today marks a significant milestone in the Navy’s partnership with NASA and the Orion Human Space Flight Program,” said Navy Commander Brett Moyes, Future Plans Branch chief, U.S. Fleet in a statement.

“The Navy is excited to support NASA’s continuing mission of space exploration. Our unique capabilities make us an ideal partner for NASA in the recovery of astronauts in the 21st century — just as we did nearly a half century ago in support of America’s quest to put a man on the moon.”

The ocean recovery of Orion will be far different from the Apollo era where the crew’s were first hoisted out of the floating capsule and the capsule then hoisted on deck of a US Navy aircraft carrier.

The next Orion water recovery test will be conducted in the open waters of the Pacific Ocean in January 2014.

Inside up close look at the Orion attached to the recovery cradle in the drained well deck of the USS Arlington recovery ship.    Credit: Ken Kremer/kenkremer.com
Inside up close look at the Orion attached to the recovery cradle in the drained well deck of the USS Arlington recovery ship. Credit: Ken Kremer/kenkremer.com

NASA’s Langley Research Center in nearby Hampton, VA is conducting an extensive drop test program in support of the Orion project.

“The Orion capsule tested today has the same mold line and dimensions as the Orion EFT-1 capsule.”

“The Orion hardware and the Delta IV Heavy booster for the EFT-1 launch are on target for launch in 2014,” Wilson told me.

Watch this NASA Video of the Orion test:

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.

The EFT-1 mission will provide engineers with critical data about Orion’s heat shield, flight systems and capabilities to validate designs of the spacecraft before it begins carrying humans to new destinations in the solar system, including an asteroid and Mars.

It will return to Earth at a speed of approximately 20,000 mph for a splashdown in the Pacific Ocean.

Right now its T Minus 1 Year and counting to liftoff of Orion EFT-1.

Ken Kremer

…………….
Learn more about Orion, Cygnus, Antares, LADEE, MAVEN, Mars rovers and more at Ken’s upcoming presentations

Sep 5/6/16/17: LADEE Lunar & Antares/Cygnus ISS Rocket Launches from Virginia”; Rodeway Inn, Chincoteague, VA, 8 PM

Oct 3: “Curiosity, MAVEN and the Search for Life on Mars – (3-D)”, STAR Astronomy Club, Brookdale Community College & Monmouth Museum, Lincroft, NJ, 8 PM

Social media and media including Ken observe the Aug. 15 Orion water recovery test from the pier at Naval Station Norfolk, VA.  Credit: NASA
Social media and media including Ken observe the Aug. 15 Orion water recovery test from the pier at Naval Station Norfolk, VA. Credit: NASA
Scott Wilson, NASA’s Orion production manager and Ken Kremer, Universe Today discuss the Aug. 15 recovery test back dropped by Orion and the USS Arlington.  Credit: Ken Kremer/kenkremer.com
Scott Wilson, NASA’s Orion production manager and Ken Kremer, Universe Today discuss the Aug. 15 recovery test back dropped by Orion and the USS Arlington. Credit: Ken Kremer/kenkremer.com

Watch Live: NASA’s Orion Parachute Test

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

NASA is testing out the parachutes for the new Orion crew vehicle, and in a first, is broadcasting it live as a Google+ Hangout from the U.S. Army’s Yuma Proving Ground in Arizona. They are also going to make something bad happen, and will be happy if it works! Watch live above (from 10:30 to 11:30 a.m. EDT July 24) or watch the replay later as an Orion test capsule is dropped from a plane at 10,700 meters (35,000 feet) to evaluate its parachutes.

Engineers will simulate a failure of one of the spacecraft’s three main parachutes, releasing it before Orion has landed.

Update: Despite a bad video feed, the test was a success.

“The closer we can get to actual flight conditions, the more confidence we gain in the system,” said Chris Johnson after the test. Johnson is project manager for the Orion capsule parachute assembly system at NASA’s Johnson Space Center in Houston. “What we saw today — other than the failures we put in on purpose — is very similar to what Orion will look like coming back during Exploration Flight Test-1’s Earth entry next year.”

One of three massive main parachutes was cut away early on purpose, and so the spacecraft was left with just two parachutes. However, the capsule still landed safely. Wednesday’s test was the highest-altitude test of a human spacecraft parachute since NASA’s Apollo Program.

During previous tests for Orion’s parachutes, a mock capsule was dropped from a height of 25,000 feet and the parachutes deployed at no higher than 22,000 feet. The extra 10,000 feet of altitude at the beginning of Wednesday’s test made the demonstration the best so far of Orion’s parachute flight and landing.

This test was in preparation for the Exploration Flight Test-1, an uncrewed test of the spacecraft that will send Orion 5,800 km (3,600 miles) away from Earth, scheduled for September 2014. Orion’s parachutes are being tested to ensure they can slow the capsule for a safe landing in the Pacific Ocean as the spacecraft reenters Earth’s atmosphere from deep space missions at speeds of up to 32,000 km/h (20,000 mph.)

NASA Alters 1st Orion/SLS Flight – Bold Upgrade to Deep Space Asteroid Harbinger Planned

NASA Orion spacecraft blasts off atop 1st Space Launch System rocket in 2017 - attached to European provided service module – on an enhanced m mission to Deep Space where an asteroid could be relocated as early as 2021. Credit: NASA

NASA Orion spacecraft blasts off atop 1st Space Launch System rocket in 2017 – attached to European provided service module – on an ambitious mission to explore Deep Space some 40,000 miles beyond the Moon, where an asteroid could be relocated as early as 2021. Credit: NASA
Story updated with further details[/caption]

NASA managers have announced a bold new plan to significantly alter and upgrade the goals and complexity of the 1st mission of the integrated Orion/Space Launch System (SLS) human exploration architecture – planned for blastoff in late 2017.

The ambitious first flight, called Exploration Mission 1 (EM-1), would be targeted to send an unpiloted Orion spacecraft to a point more than 40,000 miles (70,000 kilometers) beyond the Moon as a forerunner supporting NASA’s new Asteroid Redirect Initiative – recently approved by the Obama Administration.

The EM-1 flight will now serve as an elaborate harbinger to NASA’s likewise enhanced EM-2 mission, which would dispatch a crew of astronauts for up close investigation of a small Near Earth Asteroid relocated to the Moon’s vicinity.

Orion crew module separates from Space Launch System (SLS) upper stage. Credit: NASA
Orion crew module separates from Space Launch System (SLS) upper stage. Credit: NASA

Until recently NASA’s plan had been to launch the first crewed Orion atop the 2nd SLS rocket in 2021 to a high orbit around the moon on the EM-2 mission, said NASA Associate Administrator Lori Garver in an prior interview with me at the Kennedy Space Center.

Concept of NASA spacecraft with Asteroid capture mechanism deployed to redirect a small space rock to a stable lunar orbit for later study by astronauts aboard Orion crew capsule. Credit: NASA.
Concept of NASA spacecraft with Asteroid capture mechanism deployed to redirect a small space rock to a stable lunar orbit for later study by astronauts aboard Orion crew capsule. Credit: NASA.

The enhanced EM-1 flight would involve launching an unmanned Orion, fully integrated with the Block 1 SLS to a Deep Retrograde Orbit (DRO) near the moon, a stable orbit in the Earth-moon system where an asteroid could be moved to as early as 2021.

Orion’s mission duration would be nearly tripled to 25 days from the original 10 days.

“The EM-1 mission with include approximately nine days outbound, three to six days in deep retrograde orbit and nine days back,” Brandi Dean, NASA Johnson Space Center spokeswoman told Universe Today exclusively.

The proposed much more technologically difficult EM-1 mission would allow for an exceptionally more vigorous work out and evaluation of the design of all flight systems for both Orion and SLS before risking a flight with humans aboard.

Asteroid Capture in Progress
Asteroid Capture in Progress

A slew of additional thruster firings would exercise the engines to change orbital parameters outbound, around the moon and inbound for reentry.

The current Deep Retrograde Orbit (DRO) plan includes several thruster firings from the Orion service module, including a powered lunar flyby, an insertion at DRO, an extraction maneuver from the DRO and a powered flyby on return to Earth.

Orion would be outfitted with sensors to collect a wide variety of measurements to evaluate its operation in the harsh space environment.

“EM-1 will have a compliment of both operational flight instrumentation and development flight instrumentation. This instrumentation suite gives us the ability to measure many attributes of system functionality and performance, including thermal, stress, displacement, acceleration, pressure and radiation,” Dean told me.

The EM-1 flight has many years of planning and development ahead and further revisions prior to the 2017 liftoff are likely.

“Final flight test objectives and the exact set of instrumentation required to meet those objectives is currently under development,” Dean explained.

Orion is NASA’s next generation manned space vehicle following the retirement of NASA’s trio of Space Shuttles in 2011.

The SLS launcher will be the most powerful and capable rocket ever built by humans – exceeding the liftoff thrust of the Apollo era Moon landing booster, the mighty Saturn V.

“We sent Apollo around the moon before we landed on it and tested the space shuttle’s landing performance before it ever returned from space.” said Dan Dumbacher, NASA’s deputy associate administrator for exploration systems development, in a statement.

“We’ve always planned for EM-1 to serve as the first test of SLS and Orion together and as a critical step in preparing for crewed flights. This change still gives us that opportunity and also gives us a chance to test operations planning ahead of our mission to a relocated asteroid.”

Both Orion and SLS are under active and accelerating development by NASA and its industrial partners.

The 1st Orion capsule is slated to blast off on the unpiloted EFT-1 test flight in September 2014 atop a Delta IV Heavy rocket on a two orbit test flight to an altitude of 3,600 miles above Earth’s surface.

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
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

It will then reenter Earth’s atmosphere at speeds of about 20,000 MPH (11 km/sec) and endure temperatures of 4,000 degrees Fahrenheit in a critical test designed to evaluate the performance of Orion’s heatshield and numerous spacecraft systems.

Orion EFT-1 is already under construction at the Kennedy Space Center (KSC) by prime contractor Lockheed Martin – read my earlier story here.

Integration and stacking tests with Orion’s emergency Launch Abort System are also in progress at KSC – details here.

NASA says the SLS is also in the midst of a extensive review process called the Preliminary Design Review (PDR) to ensure that all launch vehicle components and systems will achieve the specified performance targets and be completed in time to meet the 2017 launch date. The PDR will be completed later this summer.

NASA’s goal with Orion/SLS is to send humans to the Moon and other Deep Space destinations like Asteroids and Mars for the first time in over forty years since the final manned lunar landing by Apollo 17 back in 1972.

NASA Headquarters will make a final decision on upgrading the EM-1 mission after extensive technical reviews this summer.

Ken Kremer

Schematic of Orion components. Credit: NASA
Schematic of Orion components. Credit: NASA

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