KSC and Visitor Complex Reopen in Aftermath of Hurricane Irma; with Launches Delayed and Viewing Spots Destroyed

TITUSVILLE/CAPE CANAVERAL, FL – NASA’s Kennedy Space Center, the KSC Visitor Complex and Cape Canaveral Air Force Station have reopened as of today and yesterday, respectively, in the aftermath of Cat 1 hurricane force winds from Hurricane Irma that lashed the Florida Space Coast on Sunday and Monday (Sept. 10/11) – forcing launch delays and leaving damaged and destroyed homes, buildings, infrastructure and launch viewing locations in its wake.

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NASA Studies Whether to Add Crew to 1st SLS Megarocket Moon Launch in 2019

KENNEDY SPACE CENTER, FL – At the request of the new Trump Administration, NASA has initiated a month long study to determine the feasibility of converting the first integrated unmanned launch of the agency’s new Space Launch System (SLS) megarocket and Orion capsule into a crewed mission that would propel two astronauts to the Moon and back by 2019 – 50 years after the first human lunar landing.

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NASA To Study Launching Astronauts on 1st SLS/Orion Flight

KENNEDY SPACE CENTER, FL – In a potentially major change in direction for NASA’s human spaceflight architecture, the agency is officially studying the possibility of adding a crew of astronauts to the first flight of Orion deep space crew capsule and the heavy lift Space Launch System (SLS) rocket currently in development, announced Acting NASA Administrator Robert Lightfoot.

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Major Overhaul of VAB for NASA’s SLS Mars Rocket Reaches Halfway Point With Platform Installation

Looking up to the 5 pairs of newly installed massive work platforms inside High Bay 3 of the Vehicle Assembly Building on July 28, 2016 during exclusive facility visit by Universe Today.  The new platforms are required to give technicians access to assemble NASA’s Space Launch System rocket at the Kennedy Space Center in Florida.  Credit: Ken Kremer/kenkremer.com

KENNEDY SPACE CENTER, FL – A major overhaul of the iconic Vehicle Assembly Building (VAB) readying it for launches of NASA’s SLS Mars rocket by 2018 has reached the halfway point with installation of massive new access platforms required to enable assembly of the mammoth booster at the Kennedy Space Center (KSC) – as seen firsthand during an exclusive up close facility tour by Universe Today.

“We are in the full development stage right now and roughly 50% complete with the platforms on this job,” David Sumner, GSDO Deputy Sr. project manager for VAB development work at KSC, told Universe Today in an exclusive interview inside the VAB’s High Bay 3 on July 28, amidst workers actively turning NASA’s deep space dreams into full blown reality.

Upgrading and renovating the VAB is specifically the responsibility of NASA’s Ground Systems Development and Operations Program (GSDO) at Kennedy.

Inside VAB High Bay 3 – where previous generations of space workers proudly assembled NASA’s Saturn V Moon rocket and the Space Shuttle Orbiter launch stacks – today’s crews of workers were actively installing the newly manufactured work platforms needed to process and build the agency’s Space Launch System (SLS) rocket that will soon propel our astronauts back to exciting deep space destinations.

“We are very excited. We are at the beginning of a new program!” Sumner told me. “We have the infrastructure and are getting into operations soon.”

It’s certainly an exciting time as NASA pushes forward on all fronts in a coordinated nationwide effort to get the SLS rocket with the Orion EM-1 crew vehicle bolted on top ready and rolled out to Kennedy’s pad 39B for their planned maiden integrated blastoff by Fall 2018.

SLS and Orion are at the heart of NASA’s agency wide strategy to send astronauts on a ‘Journey to Mars’ by the 2030s.

SLS is the most powerful booster the world has even seen and is designed to boost NASA astronauts in the agency’s Orion crew capsule on exciting missions of exploration to deep space destinations including the Moon, Asteroids and Mars – venturing further out than humans ever have before!

I walked into High Bay 3, scanned all around and up to the ceiling some 525 feet away and was thrilled to see a bustling construction site – the future of humans voyages in deep space unfolding before my eyes. As I looked up to see the newly installed work platforms, I was surrounded by the constant hum of plenty of hammering, cutting, welding, banging and clanging and workers moving equipment and gear around.

Altogether a total of 10 levels of work platform levels will be installed in High Bay 3 – labeled K to A, from bottom to top. Each level consists of two platforms, denoted as the North and South side platforms.

What’s the status today?

“We are looking up at 5 of 10 platform levels with 10 of 20 platforms halves installed here. A total of ten levels are being installed,” Sumner explained.

“We are installing them from the bottom up. The bottom five levels are installed so far.”

“We are up to about the 190 foot level right now with Platform F installation. Then we are going up to about the 325 foot level with the 10th platform [Platform A].

“So there are 10 levels for EM-1.”

So much work was visible and actively in progress I definitely got the feeling from the ground up that NASA is moving fast into a new post shuttle Era – dominated by the mammoth new SLS making its assembly debut inside these hallowed walls some 18 months or so from today.

“The work today is some outfitting on the platforms overhead here, as well as more work on the platform halves sitting in the transfer aisle and High Bay 4 to get them ready to lift and install into High Bay 3.”

“Overhead steel work is also ongoing here in High Bay 3 with additional steel work going vertical for reinforcement and mounting brackets for all the platforms going vertically.”

“So quite a few work locations are active with different crews and different groups.”

Two additional new platform halves are sitting and in the VAB transfer aisle and next in line for installation. With two more awaiting in VAB High Bay 4. Fabrication of additional platform halves is ongoing at KSC’s nearby Oak Hill facility.

“The rest are being fabricated in our Oak Hill facility. So we have almost everything on site so far.”

Hensel Phelps is the general contractor for the VAB transformation. Subcontractors include S&R, Steel LLC, Sauer Inc., Jacobs and Beyel Bros Crane and Rigging.

The work platforms enable access to the SLS rocket at different levels up and down the over 300 foot tall rocket topped by the Orion crew capsule. They will fit around the outer mold line of SLS – including the twin solid rocket boosters, the core stage, and upper stage – and Orion.

The SLS core stage is being manufactured at NASA’s Michoud Assembly Facility in New Orleans, where I recently inspected the first completed liquid hydrogen tank test article – as reported here. Orion EM-1 is being manufactured here at Kennedy – as I reported here.

The platforms will provide access for workers to assemble, process and test all the SLS and Orion components before rolling out to Launch Complex 39B – which is also undergoing a concurrent major renovation and overhaul.

As of today, five of the ten levels of platforms are in place.

Each of the giant platforms made of steel measures about 38 feet long and close to 62 feet wide. They weigh between 300,000 and 325,000 pounds.

The most recently installed F North and South platforms were put in place on the north and south walls of the high bay on July 15 and 19, respectively.

How are the platforms installed ?

The platforms are carefully lifted into place by workers during a process that lasts about four hours.

“The 325 and 250 ton overhead facility cranes are used to [slowly] lift and move the platform halves back and forth between the VAB transfer aisle and High Bay 4 and into the SLS High Bay 3.”

Then they are attached to rail beams on the north and south walls of the high bay.

Construction workers from Beyel Bros Crane and Rigging also use a Grove 40 ton all terrain crane. It is also outfitted with man baskets to get to the places that cannot be reached by scaffolding in High Bay 3.
Installation of the remaining five levels of platforms should be completed by mid-2017.

“The job will be done by the middle of 2017. All the construction work will be done,” Sumner explained.

“Then we will get into our verification and validations with the Mobile Launcher (ML). Then the ML will roll in here around middle to late 2017 [for checkouts and testing] and then roll out to the pad [for more testing]. After that it will roll back in here. Then we will be ready to stack the SLS starting after that!”

The platforms will be tested beginning later this year, starting with the lowest platforms at the K-level, and working all the way up to the top, the A-level.

The platforms are attached to a system of rail beams that “provide structural support and contain the drive mechanisms to retract and extend the platforms,” according to a NASA fact sheet.

“Each platform will reside on four Hillman roller systems on each side – much like a kitchen drawer slides in and out. A mechanical articulated tray also moves in and out with each platform.”

The F-level platforms are located about 192 feet above the VAB floor.

“They will provide access to the SLS core stage (CS) intertank for umbilical mate operations. The “F-1” multi-level ground support equipment access platform will be used to access the booster forward assemblies and the CS to booster forward attach points. The upper level of F-1 will be used to remove the lifting sling used to support forward assembly mate for booster stacking operations.”

“Using the five platforms that are now installed, workers will have access to all of the Space Launch System rocket’s booster field joints and forward skirts, the core stage intertank umbilical and interface plates,” says Mike Bolger, GSDO program manager at Kennedy.

‘NASA is transforming KSC into a launch complex for the 21st Century,’ as KSC Center Director and former shuttle commander Bob Cabana often explains.

So it was out with the old and in with the new to carry out that daunting task.

“We took the old shuttle platforms out, went down to the [building] structure over the past few years and are now putting up the new SLS platforms,” Sumner elaborated.

“All the demolition work was done a few years ago. So we are in the full development stage right now and roughly 50% complete with the platforms on this job.”

And after NASA launches EM-1, significantly more VAB work lies ahead to prepare for the first manned Orion launch on the EM-2 mission set for as soon as 2021 – because it will feature an upgraded and taller version of the SLS rocket – including a new upper stage.

“For EM-2, the plan right now is we will add two more levels and relocate three more. So we will do some adjustments and new installations in the upper levels for EM-2.”

“It’s been an honor to be here and work here in the VAB every day – and prepare for the next 50 years of its life.”

“We are at the beginning of a new program. We have the infrastructure and are getting into operations soon,” Sumner said. “We have hopefully got a long way to go on the future of space exploration, with many decades of exploration ahead.”

“We are on a ‘Journey to Mars’ and elsewhere. So this is the beginning of all that. It’s very exciting!”

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

Ken Kremer

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NASA Welds Together 1st SLS Hydrogen Test Tank for America’s Moon/Mars Rocket – Flight Unit in Progress

The first liquid hydrogen tank, also called the qualification test article, for NASA's new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine on July 22, 2016 after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans.  Credit: Ken Kremer/kenkremer.com

MICHOUD ASSEMBLY FACILITY, NEW ORLEANS, LA – NASA has just finished welding together the very first fuel tank for America’s humongous Space Launch System (SLS) deep space rocket currently under development – and Universe Today had an exclusive up close look at the liquid hydrogen (LH2) test tank shortly after its birth as well as the first flight tank, during a tour of NASA’s New Orleans rocket manufacturing facility on Friday, July 22, shortly after completion of the milestone assembly operation.

“We have just finished welding the first liquid hydrogen qualification tank article …. and are in the middle of production welding of the first liquid hydrogen flight hardware tank [for SLS-1] in the big Vertical Assembly Center welder!” explained Patrick Whipps, NASA SLS Stages Element Manager, in an exclusive hardware tour and interview with Universe Today on July 22, 2016 at NASA’s Michoud Assembly Facility (MAF) in New Orleans.

“We are literally putting the SLS rocket hardware together here at last. All five elements to put the SLS stages together [at Michoud].”

This first fully welded SLS liquid hydrogen tank is known as a ‘qualification test article’ and it was assembled using basically the same components and processing procedures as an actual flight tank, says Whipps.

“We just completed the liquid hydrogen qualification tank article and lifted it out of the welding machine and put it into some cradles. We will put it into a newly designed straddle carrier article next week to transport it around safely and reliably for further work.”

SLS is the most powerful booster the world has even seen and one day soon will propel NASA astronauts in the agency’s Orion crew capsule on exciting missions of exploration to deep space destinations including the Moon, Asteroids and Mars – further out than humans have ever ventured before!

The LH2 ‘qualification test article’ was welded together using the world’s largest welder – known as the Vertical Assembly Center, or VAC, at Michoud.

And it’s a giant! – measuring approximately 130-feet in length and 27.6 feet (8.4 m) in diameter.

See my exclusive up close photos herein documenting the newly completed tank as the first media to visit the first SLS tank. I saw the big tank shortly after it was carefully lifted out of the welder and placed horizontally on a storage cradle on Michoud’s factory floor.

Finishing its assembly after years of meticulous planning and hard work paves the path to enabling the maiden test launch of the SLS heavy lifter in the fall of 2018 from the Kennedy Space Center (KSC) in Florida.

The qual test article is the immediate precursor to the actual first LH2 flight tank now being welded.

‘We will finish welding the liquid hydrogen and liquid oxygen flight tanks by September,” Whipps told Universe Today.

Technicians assembled the LH2 tank by feeding the individual metallic components into NASA’s gigantic “Welding Wonder” machine – as its affectionately known – at Michoud, thus creating a rigid 13 story tall structure.

The welding work was just completed this past week on the massive silver colored structure. It was removed from the VAC welder and placed horizontally on a cradle.

I watched along as the team was also already hard at work fabricating SLS’s first liquid hydrogen flight article tank in the VAC, right beside the qualification tank resting on the floor.

Welding of the other big fuel tank, the liquid oxygen (LOX) qualification and flight article tanks will follow quickly inside the impressive ‘Welding Wonder’ machine. The LH2 and LOX tanks sit on top of one another inside the SLS outer skin.

The SLS core stage – or first stage – is mostly comprised of the liquid hydrogen and liquid oxygen cryogenic fuel storage tanks which store the rocket propellants at super chilled temperatures. Boeing is the prime contractor for the SLS core stage.

To prove that the new welding machines would work as designed, NASA opted “for a 3 stage assembly philosophy,” Whipps explained.

Engineers first “welded confidence articles for each of the tank sections” to prove out the welding techniques “and establish a learning curve for the team and test out the software and new weld tools. We learned a lot from the weld confidence articles!”

“On the heels of that followed the qualification weld articles” for tank loads testing.

“The qualification articles are as ‘flight-like’ as we can get them!

With the expectation that there are still some tweaks coming.”

“And finally that leads into our flight hardware production welding and manufacturing the actual flight unit tanks for launches.”

“All the confidence articles and the LOX qualification article are complete!”

What’s the next step for the LH2 tank?

The test article tank will be outfitted with special sensors and simulators attached to each end to record reams of important engineering data, thereby extending it to about 185 feet in length.

Thereafter it will loaded onto the Pegasus barge and shipped to NASA’s Marshall Space Flight Center in Huntsville, Alabama, for structural loads testing on one of two new test stands currently under construction for the tanks. The tests are done to prove that the tanks can withstand the extreme stresses of spaceflight and safely carry our astronauts to space.

“We are manufacturing the simulators for each of the SLS elements now for destructive tests – for shipment to Marshall. It will test all the stress modes, and finally to failure to see the process margins.”

The SLS core stage builds on heritage from NASA’s Space Shuttle Program and is based on the shuttle’s External Tank (ET). All 135 ET flight units were built at Michoud during the thirty year long shuttle program by Lockheed Martin.

“We saved billions of dollars and years of development effort vs. starting from a clean sheet of paper design, by taking aspects of the shuttle … and created an External Tank type generic structure – with the forward avionics on top and the complex engine section with 4 engines (vs. 3 for shuttle) on the bottom,” Whipps elaborated.

“This is truly an engineering marvel like the External Tank was – with its strength that it had and carrying the weight that it did. If you made our ET the equivalent of a Coke can, our thickness was about 1/5 of a coke can.”

“It’s a tremendous engineering job. But the ullage pressures in the LOX and LH2 tanks are significantly more and the systems running down the side of the SLS tank are much more sophisticated. Its all significantly more complex with the feed lines than what we did for the ET. But we brought forward the aspects and designs that let us save time and money and we knew were effective and reliable.”

The SLS core stage is comprised of five major structures: the forward skirt, the liquid oxygen tank (LOX), the intertank, the liquid hydrogen tank (LH2) and the engine section.

The LH2 and LOX tanks feed the cryogenic propellants into the first stage engine propulsion section which is powered by a quartet of RS-25 engines – modified space shuttle main engines (SSMEs) – and a pair of enhanced five segment solid rocket boosters (SRBs) also derived from the shuttles four segment boosters.

The tanks are assembled by joining previously manufactured dome, ring and barrel components together in the Vertical Assembly Center by a process known as friction stir welding. The rings connect and provide stiffness between the domes and barrels.

The LH2 tank is the largest major part of the SLS core stage. It holds 537,000 gallons of super chilled liquid hydrogen. It is comprised of 5 barrels, 2 domes, and 2 rings.

The LOX tank holds 196,000 pounds of liquid oxygen. It is assembled from 2 barrels, 2 domes, and 2 rings and measures over 50 feet long.

The material of construction of the tanks has changed compared to the ET.

“The tanks are constructed of a material called the Aluminum 2219 alloy,” said Whipps. “It’s a ubiquosly used aerospace alloy with some copper but no lithium, unlike the shuttle superlightweight ET tanks that used Aluminum 2195. The 2219 has been a success story for the welding. This alloy is heavier but does not affect our payload potential.”

“The intertanks are the only non welded structure. They are bolted together and we are manufacturing them also. It’s much heavier and thicker.”

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

NASA’s Vehicle Assembly Center is the world’s largest robotic weld tool. The domes and barrels are assembled from smaller panels and piece parts using other dedicated robotic welding machines at Michoud.

The total weight of the whole core stage empty is 188,000 pounds and 2.3 million pounds when fully loaded with propellant. The empty ET weighed some 55,000 pounds.

Considering that the entire Shuttle ET was 154-feet long, the 130-foot long LH2 tank alone isn’t much smaller and gives perspective on just how big it really is as the largest rocket fuel tank ever built.

“So far all the parts of the SLS rocket are coming along well.”

“The Michoud SLS workforce totals about 1000 to 1500 people between NASA and the contractors.”

Every fuel tank welded together from now on after this series of confidence and qualification LOX and LH2 tanks will be actual flight article tanks for SLS launches.

“There are no plans to weld another qualification tank after this,” Nesselroad confirmed to me.

What’s ahead for the SLS-2 core stage?

“We start building the second SLS flight tanks in October of this year – 2016!” Nesselroad stated.

The world’s largest welder was specifically designed to manufacture the core stage of the world’s most powerful rocket – NASA’s SLS. The Vertical Assembly Center welder was officially opened for business at NASA’s Michoud Assembly Facility in New Orleans on Friday, Sept. 12, 2014.

NASA Administrator Charles Bolden was personally on hand for the ribbon-cutting ceremony at the base of the huge VAC welder.

The state-of-the-art welding giant stands 170 feet tall and 78 feet wide. It complements the world-class welding toolkit being used to assemble various pieces of the SLS core stage including the domes, rings and barrels that have been previously manufactured.

The maiden test flight of the SLS/Orion 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.

Although the SLS-1 flight in 2018 will be uncrewed, NASA plans to launch astronauts on the SLS-2/EM-2 mission slated for the 2021 to 2023 timeframe.

The exact launch dates fully depend on the budget NASA receives from Congress and who is elected President in the November 2016 election and whether they maintain or modify NASA’s objectives.

“If we can keep our focus and keep delivering, and deliver to the schedules, the budgets and the promise of what we’ve got, I think we’ve got a very capable vision that actually moves the nation very far forward in moving human presence into space,” said William Gerstenmaier, associate administrator for the Human Exploration and Operations Mission Directorate at NASA Headquarters in Washington, during the post QM-2 SRB test media briefing in Utah last month.

“This is a very capable system. It’s not built for just one or two flights. It is actually built for multiple decades of use that will enable us to eventually allow humans to go to Mars in the 2030s.”

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

Ken Kremer

The post NASA Welds Together 1st SLS Hydrogen Test Tank for America’s Moon/Mars Rocket – Flight Unit in Progress appeared first on Universe Today.

NASA’s Orion EM-1 Crew Module Passes Critical Pressure Tests

Lockheed Martin engineers and technicians prepare the Orion pressure vessel for a series of tests inside the proof pressure cell in the Neil Armstrong Operations and Checkout Building at NASA's Kennedy Space Center in Florida. Photo credit: NASA/Kim Shiflett

The next Orion crew module in line to launch to space on NASA’s Exploration Mission-1 (EM-1) has passed a critical series of proof pressure tests which confirm the effectiveness of the welds holding the spacecraft structure together.

Engineers and technicians conducted the pressure tests on the Orion EM-1 pressure vessel, which was welded together at NASA’s Michoud Assembly Facility in New Orleans and then shipped to NASA’s Kennedy Space Center in Florida just 3 months ago.

The pressure vessel is the structural backbone for the vehicles that will launch American astronauts to deep space destinations.

“The tests confirmed that the weld points of the underlying structure will contain and protect astronauts during the launch, in-space, re-entry and landing phases on the Exploration Mission 1 (EM-1), when the spacecraft performs its first uncrewed test flight atop the Space Launch System rocket,” said NASA.

After flying to KSC on Feb 1, 2016 inside NASA’s unique Super Guppy aircraft, this “new and improved” Orion EM-1 pressure vessel was moved to the Neil Armstrong Operations and Checkout (O&C) Building for final assembly by prime contractor Lockheed Martin into a flight worthy vehicle.

Since then, technicians have worked to meticulously attach hundreds of strain gauges to the interior and exterior surfaces of the vehicle to prepare for the pressure tests.

The strain gauges provide real time data to the analysts monitoring the changes during the pressurization.

Orion was moved to a test stand inside the proof pressure cell high bay and locked inside behind large doors.

Lockheed Martin engineers then incrementally increased the pressure in the proof testing cell in a series of steps over two days. They carefully monitored the results along the way and how the spacecraft reacted to the stresses induced by the pressure increases.

The maximum pressure reached was 1.25 times normal atmospheric pressure – which exceeds the maximum pressure it is expected to encounter on orbit.

“We are very pleased with the performance of the spacecraft during proof pressure testing,” said Scott Wilson, NASA manager of production operations for the Orion Program.

“The successful completion of this test represents another major step forward in our march toward completing the EM-1 spacecraft, and ultimately, our crewed missions to deep space.”

With the pressure testing satisfactorily completed, technicians will move Orion back to birdcage assembly stand for the “intricate work of attaching hundreds of brackets to the vessel’s exterior to hold the tubing for the vehicle’s hydraulics and other systems.”

To prepare for launch in 2018, engineers and technicians from NASA and prime contractor Lockheed Martin will spend the next two years meticulously installing all the systems amounting to over 100,000 components and gear required for flight.

This particular ‘Lunar Orion’ crew module is intended for blastoff to the Moon in 2018 on NASA’s Exploration Mission-1 (EM-1) atop the agency’s mammoth new Space Launch System (SLS) rocket, simultaneously under development. The pressurized crew module serves as the living quarters for the astronauts comprising up to four crew members.

EM-1 itself is a ‘proving ground’ mission that will fly an unmanned Orion thousands of miles beyond the Moon, further than any human capable vehicle, and back to Earth, over the course of a three-week mission.

The 2018 launch of NASA’s Orion on the unpiloted EM-1 mission counts as the first joint flight of SLS and Orion, and the first flight of a human rated spacecraft to deep space since the Apollo Moon landing era ended more than 4 decades ago.

Orion is designed to send astronauts deeper into space than ever before, including missions to the Moon, asteroids and the Red Planet.

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

Ken Kremer

The post NASA’s Orion EM-1 Crew Module Passes Critical Pressure Tests appeared first on Universe Today.

NASA Welds First Flight Section of SLS Core Stage for 2018 Maiden Launch

Space Launch System (SLS) core stage engine section finishes welding at the Vertical Assembly Center at NASA's Michoud Assembly Facility in New Orleans for maiden flight of SLS rocket. Credit: NASA

One weld at a time, the flight hardware for NASA’s mammoth new Space Launch System (SLS) booster has at last started taking shape, promising to turn years of planning and engineering discussions into reality and a rocket that will one day propel our astronauts on a ‘Journey to Mars.’

The first actual SLS flight hardware has been assembled, leaping from engineering blueprints on computer screens to individual metallic components that technicians are feeding into NASA’s gigantic “Welding Wonder” machine at the agency’s Michoud Assembly Facility in New Orleans.

Technicians are bending metal and have now finished welding together the pieces of flight hardware forming the first major SLS flight component – namely the engine section that sits at the base of the SLS core stage.

The engine section of the core stage will house the four RS-25 engines that will power the maiden launch of SLS and NASA’s Orion deep space manned spacecraft in late 2018.

The core stage towers over 212 feet (64.6 meters) tall, sports a diameter of 27.6 feet (8.4 m) and stores the cryogenic liquid hydrogen and liquid oxygen that feeds and fuels the boosters RS-25 engines.

SLS will be the most powerful rocket the world has ever seen. It will propel astronauts in the Orion capsule on deep space missions, first back to the Moon by around 2021, then to an asteroid around 2025 and then beyond to the Red Planet in the 2030s – NASA’s overriding and agency wide goal.

The SLS core stage welding work is carried out in the massive 170-foot-tall Vertical Assembly Center (VAC) at Michoud. Boeing is the prime contractor for the SLS core stage.

On Sept. 12, 2014, NASA Administrator Charles Bolden officially unveiled VAC as the world’s largest welder at Michoud.

“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.

Each of the RS-25’s engines generates some 500,000 pounds of thrust, fueled by cryogenic liquid hydrogen and liquid oxygen. They are recycled for their original use as space shuttle main engines

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.

The SLS weld team has been busy. Technicians have already assembled a qualification version of the engine section on the Vertical Assembly Center at Michoud. Later this year it will be shipped to NASA’s Marshall Space Flight Center in Huntsville, Alabama, to undergo structural loads testing.

In March, they also completed welding of a liquid oxygen tank confidence article on the Vertical Assembly Center. And in February they welded the liquid hydrogen tank confidence article.

According to the current schedule, NASA plans to finish all welding for the core stage — including confidence, qualification and flight hardware — of the SLS-1 rocket sometime this summer.

Engineers are constructing the confidence and qualification hardware units to verify that the welding equipment and procedures work exactly as planned.

“The confidence will also be used in developing the application process for the thermal protection system, which is the insulation foam that gives the tank its orange color,” say NASA officials.

Altogether , the SLS first stage propulsion comprises the 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 maiden test flight of the SLS/Orion 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.

Meanwhile the welded skeletal backbone for the Orion EM-1 mission recently arrived at the Kennedy Space Center on Feb. 1 for outfitting with all the systems and subsystems necessary for flight.

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

The post NASA Welds First Flight Section of SLS Core Stage for 2018 Maiden Launch appeared first on Universe Today.

NASA’s Orion Crew Module Backbone Arrives at KSC Aboard Super Guppy for Exploration Mission-1

NASA’s Orion EM-1 crew module pressure vessel arrived at the Kennedy Space Center’s Shuttle Landing Facility tucked inside NASA’s Super Guppy aircraft on Feb 1, 2016. The Super Guppy opens its hinged nose to unload cargo.  Credit: Ken Kremer/kenkremer.com

KENNEDY SPACE CENTER – Looking amazingly like a fish flying across the skies high above the Florida space coast, NASA’s unique Super Guppy aircraft loaded with the structural backbone for NASA’s next Orion crew module, swooped in for a landing at the Kennedy Space Center on Monday afternoon, Feb. 1.

The Super Guppy, with the recently completed pressure vessel for the Orion crew module tucked safely inside, touched down gently at about 3:45 p.m. Monday on the same runway at the Shuttle Landing Facility (SLF) where NASA’s now retired orbiters formerly returned from space voyages. The landing strip is now operated by Space Florida.

Orion’s arrival at KSC marks a major milestone on the road to starting NASA’s ‘Journey to Mars’ initiative.

This Lunar Orion vehicle is destined for blastoff to the Moon in 2018 on NASA’s Exploration Mission-1 (EM-1) atop the agency’s mammoth Space Launch System (SLS) rocket.

EM-1 is a ‘proving ground’ mission that will fly an unmanned Orion thousands of miles beyond the Moon, further than any human capable vehicle, and back to Earth, over the course of a three-week mission.

“This is an exciting day for NASA,” NASA Orion program manager Scott Wilson told Universe Today, at the shuttle landing strip after Orion’s safe arrival.

The olive green colored pressure vessel is the spacecraft’s underlying structure on which all of the spacecraft’s systems and subsystems are built and integrated prior to liftoff.

Earlier in the day, Orion departed from NASA’s Michoud Assembly Facility in New Orleans, where the vehicle’s pressure vessel was welded into shape by engineers using an advanced friction-stir welding process.

The crated Orion has packed into the aquatic looking Super Guppy’s cargo compartment that measures 25 feet tall, 25 feet wide and 111 feet long and can carry more than 26 tons.

The EM-1 pressure vessel weighs about 2700 lbs. It stands 10 feet high and is nearly 5 meters in diameter. After installing the thermal protection system, the finished Orion flight capsule will be about 11 feet high and 16.5 feet wide.

The aircraft possesses a unique hinged nose that opens at the front end over 200 degrees. This permits large pieces of cargo, like the voluminous Orion pressure vessel and heat shield, to be easily loaded and unloaded from the front.

Indeed the aircrafts nose was promptly opened less than a hour after touchdown at Kennedy’s SLF to begin the delicate unloading and uncrating process.

The next step is to transport Orion a few miles down the road to KSC’s Neil Armstrong Operation and Checkout Building (O & C). There, engineers from NASA and prime contractor Lockheed Martin will spend the next two years outfitting Orion’s backbone for launch in late 2018.

The team will install all the systems and subsystems for its inaugural flight to the Moon and back.

These systems include the heat shield, thermal protection, propulsion, avionics, computers, plumbing, electrical, life support, parachutes and much more.

The pressure vessel itself is comprised of seven large aluminum pieces that Michoud technicians began welding together in September 2015 using the highly precise state-of-the-art process called friction-stir welding.

The last of the seven friction-stir welds to assemble the primary structure for NASA’s EM-1 capsule was finished on Jan. 13.

Overall this is the third Orion capsule that NASA has built, following the Ground Test Article (GTA), which did not fly, and the EFT-1 capsule which successfully launched just over one year ago on Dec. 5, 2014.

There have been many lessons learned and over that time. Among the advances are that engineers have reduced the number of welds from 33 to 7. As a result of needing so many fewer welds, the team has saved over 700 pounds of weight which can be directly converted into up mass.

The 2018 launch of NASA’s Orion on an unpiloted flight dubbed Exploration Mission, or EM-1, counts as the first joint flight of SLS and Orion, and the first flight of a human rated spacecraft to deep space since the Apollo Moon landing era ended more than 4 decades ago.

Orion is designed to send astronauts deeper into space than ever before, including missions to the Moon, asteroids and the Red Planet.

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

Ken Kremer

The post NASA’s Orion Crew Module Backbone Arrives at KSC Aboard Super Guppy for Exploration Mission-1 appeared first on Universe Today.

NASA Awards Contract to Aerojet Rocketdyne to Restart RS-25 Engine Production for SLS Mars Rocket

NASA took another big step on the path to propel our astronauts back to deep space and ultimately on to Mars with the long awaited decision to formally restart production of the venerable RS-25 engine that will power the first stage of the agency’s mammoth Space Launch System (SLS) heavy lift rocket, currently under development. […]

NASA Awards Contract to Aerojet Rocketdyne to Restart RS-25 Engine Production for SLS Mars Rocket

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