Delta IV Archives

September 9, 2014December 23, 2015 by Ken Kremer

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Ken Kremer

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

Orion EFT-1 capsule under construction inside the Structural Assembly Jig at the Operations and Checkout Building (O & C) at the Kennedy Space Center (KSC); Jules Schneider, Orion Project Manager for Lockheed Martin and Ken Kremer, Universe Today. Credit: Ken Kremer - kenkremer.com — Orion EFT-1 capsule under construction inside the Structural Assembly Jig at the Operations and Checkout Building (O & C) at the Kennedy Space Center (KSC); Jules Schneider, Orion Project Manager for Lockheed Martin and Ken Kremer, Universe Today. Credit: Ken Kremer – kenkremer.com

August 30, 2014December 23, 2015 by Ken Kremer

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Ken Kremer

June 28, 2014December 23, 2015 by Ken Kremer

NASA’s Orion Deep Space Capsule Completes Most Complex Parachute Test Ahead of Maiden Launch

A test version of NASA’s Orion manned spacecraft descends under its three main parachutes above the U.S. Army Proving Ground in Arizona in the agency’s most difficult test of the parachutes system’s performance to prepare Orion for its first trip to space in December 2014. Credit: NASA/Rad Sinyak

A test version of NASA’s Orion deep space capsule has completed its most complex and last full flight-like parachute drop test on June 25 ahead of the maiden launch on the EFT-1 mission now slated for early December 2014.

The descent test was conducted at an altitude of 35,000 feet over the Arizona desert at the U.S. Army’s Yuma Proving Ground by pulling the test vehicle out of a huge C-17 cargo aircraft.

The test also included the addition of several added stress tests to check out the ability of the parachute system to compensate and examine capsule and astronaut crew survival via several potential failure modes.

For example, engineers rigged one of the main parachutes to skip the intermediate phase of the three-phase process to unfurl each of Orion’s three parachutes, called reefing.

“This tested whether one of the main parachutes could go directly from opening a little to being fully open without an intermediary step, proving the system can tolerate potential failures,” according to NASA.

The goal is to prove that that parachute system will slow Orion to ensure a safe landing speed for the astronaut crews returning from deep space missions to the Moon, Asteroids and eventually Mars.

“We’ve put the parachutes through their paces in ground and airdrop testing in just about every conceivable way before we begin sending them into space on Exploration Flight Test (EFT)-1 before the year’s done,” said Orion Program Manager Mark Geyer in a state

“The series of tests has proven the system and will help ensure crew and mission safety for our astronauts in the future.”

Orion is slated to launch on its inaugural unmanned EFT-1 test flight in December 2014 atop the mammoth, triple barreled United Launch Alliance (ULA) Delta IV Heavy rocket from Cape Canaveral, Florida.

This test also marked the last time that the entire parachute sequence involving the deployment of all three 116 foot-wide main chutes will be tested before the December launch.

For some of the parachutes, this was the highest altitude drop test attempted.

“Engineers also put additional stresses on the parachutes by allowing the test version of Orion to free fall for 10 seconds, which increased the vehicle’s speed and aerodynamic pressure,” NASA noted in a statement.

The parachute deployment and unfurling can only begin after jettisoning of the spacecraft’s forward bay cover. The chutes are housed below the cover which protects the chutes until reentry into Earth’s atmosphere.

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.

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

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

The parachute system comprising of two drogue parachutes and a trio of main parachutes – nearly the size of a football field – will then unfurl to slow Orion down to just 20 mph for a safe splashdown and recovery by the US Navy in the Pacific Ocean.

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.

Another drop test scheduled for August will test the combined failure of one drogue parachute and one main parachute, as well as new parachute design features, says NASA.

Meanwhile, Orion’s prime contractor Lockheed Martin is finishing assembly and test operations of the EFT-1 capsule inside the Operations and Checkout Facility (O & C) at the Kennedy Space Center (KSC) flying in December’s launch

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

Ken Kremer

June 10, 2014December 23, 2015 by Ken Kremer

Engineers Start Stacking Operations for Maiden Launch of NASA’s Orion Deep Space Test Capsule

The Orion crew module for Exploration Flight Test-1 is shown in the Final Assembly and System Testing (FAST) Cell, positioned over the service module just prior to mating the two sections together. Credit: NASA/Rad Sinyak
Story updated[/caption]

KENNEDY SPACE CENTER, FL- Engineers have begun stacking operations for NASA’s maiden Orion deep space test capsule at the Kennedy Space Center (KSC) achieving a major milestone leading to its first blastoff from the Florida Space Coast less than six months from today.

The excitement is mounting as final assembly of NASA’s Orion crew vehicle into its launch configuration started on Monday, June 9, inside the Operations and Checkout (O&C) Facility at Kennedy.

Orion will eventually carry humans to destinations far beyond low Earth orbit on new voyages of scientific discovery in our solar system.

“Orion is the next step in our journey of exploration,” said NASA Associate Administrator Robert Lightfoot at a recent KSC media briefing.

“This mission is a stepping stone on NASA’s journey to Mars. The EFT-1 mission is so important to NASA.”

Orion is slated to launch on its inaugural unmanned test flight in December 2014 atop the mammoth, triple barreled United Launch Alliance (ULA) Delta IV Heavy rocket.

The main elements of the Orion spacecraft stack include the crew module (CM), service module (SM) and the launch abort system (LAS).

On Monday, technicians from Orion’s prime contractor Lockheed Martin began aligning and stacking the crew module on top of the already completed service module in the Final Assembly and System Testing (FAST) Cell in the O & C facility at KSC.

“Ballast weights were added to ensure that the crew module’s center of gravity can achieve the appropriate entry and descent performance and also ensure that the vehicle lands in the correct orientation to reduce structural impact loads,” according to Lockheed Martin.

Engineers will remain busy throughout this week continuing to work at a 24/7 pace to get Orion ready for the December liftoff.

Orion heat shield attached to the bottom of the capsule by engineers during assembly work inside the Operations and Checkout High Bay facility at KSC. Credit: NASA

The next steps involve completing the power and fluid umbilical connections between the CM and SM and firmly bolting the two modules together inside the FAST cell.

An exhaustive series of electrical, avionic and radio frequency tests will follow. The team will then conduct final systems checks to confirm readiness for flight.

The LAS will then be stacked on top. The entire stack will then be rolled out to the launch pad for integration with the Delta IV Heavy rocket.

The CM/SM stacking operation was able to move forward following the successful attachment of the world’s largest heat shield onto the bottom of the CM in late May. Read my prior story – here.

“Now that we’re getting so close to launch, the spacecraft completion work is visible every day,” said Mark Geyer, NASA’s Orion Program manager in a statement.

“Orion’s flight test will provide us with important data that will help us test out systems and further refine the design so we can safely send humans far into the solar system to uncover new scientific discoveries on future missions.”

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

Orion is NASA’s next generation human rated vehicle now under development to replace the now retired space shuttle. The state-of-the-art spacecraft will carry America’s astronauts on voyages venturing farther into deep space than ever before – past the Moon to Asteroids, Mars and Beyond!

No humans have flown beyond low Earth orbit in more than four decades since Apollo 17, NASA’s final moon landing mission launched in December 1972.

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

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

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.

“We will test the heat shield, the separation of the fairing and exercise over 50% of the eventual software and electronic systems inside the Orion spacecraft. We will also test the recovery systems coming back into the Pacific Ocean,” said Lightfoot.

“Orion EFT-1 is really exciting as the first step on the path of humans to Mars,” said Lightfoot. “It’s a stepping stone to get to Mars.”

“We will test the capsule with a reentry velocity of about 85% of what to expect on returning [astronauts] from Mars.”

Two of the three United Launch Alliance (ULA) Delta IV heavy boosters for NASA’s upcoming Orion Exploration Flight Test-1 (EFT-1) mission were unveiled during a media event inside the Horizontal Integration Facility at Launch Complex 37 at Cape Canaveral Air Force Station in Florida on March 17, 2014. Credit: Ken Kremer - kenkremer.com — Two of the three United Launch Alliance (ULA) Delta IV heavy boosters for NASA’s upcoming Orion Exploration Flight Test-1 (EFT-1) mission were unveiled during a media event inside the Horizontal Integration Facility at Launch Complex 37 at Cape Canaveral Air Force Station in Florida on March 17, 2014. Credit: Ken Kremer – kenkremer.com

Concurrently, new American-made private crewed spaceships are under development by SpaceX, Boeing and Sierra Nevada – with funding from NASA’s Commercial Crew Program (CCP) – to restore US capability to ferry US astronauts to the International Space Station (ISS) and back to Earth by late 2017.

Read my exclusive new interview with NASA Administrator Charles Bolden explaining the importance of getting Commercial Crew online to expand our reach into space- here.

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

Ken Kremer

May 31, 2014December 23, 2015 by Ken Kremer

World’s Largest Heat Shield Attached to NASA’s Orion Crew Capsule for Crucial Fall 2014 Test Flight

Lockheed Martin and NASA engineers are installing the largest heat shield ever built onto the Orion EFT-1 spacecraft’s crew module at the Kennedy Space Center. Liftoff is slated for late Fall 2014. Credit: Lockheed Martin
Story updated[/caption]

In a key milestone, technicians at the Kennedy Space Center (KSC) in Florida have attached the world’s largest heat shield to a pathfinding version of NASA’s Orion crew capsule edging ever closer to its inaugural unmanned test flight later this Fall on a crucial mission dubbed Exploration Flight Test-1 (EFT-1).

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

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

The heat shield measures 16.5 feet (5 m) in diameter.

Lockheed Martin and NASA technicians mated the heat shield to the bottom of the capsule during assembly work inside the Operations and Checkout High Bay facility at KSC.

“Holes were drilled into the heat shield from the inside to the outside at the structural attached points at the underside of the crew module,” said Jules Schneider, Orion Project manager for Lockheed Martin at KSC, during a recent exclusive interview by Universe Today inside the Orion clean room at KSC.

“Then its opened up from the outside and bolted in place underneath. Closeout plugs made of Avcoat are then installed to close it up and seal the gaps,” Schneider explained.

The heat shield is constructed from a single seamless piece of Avcoat ablator, that was applied by engineers at Textron Defense System near Boston, Mass.

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

The ablative material will wear away as it heats up during the capsules atmospheric re-entry thereby preventing the 4000 degree F heat from being transferred to the rest of the capsule and saving it and the human crew from utter destruction.

Coming together! Orion's heat shield and crew module in position for mating operations at NASA KSC. Credit: NASA — Coming together! Orion’s heat shield and crew module in position for mating operations at NASA KSC. Credit: NASA

Orion EFT-1 is slated to launch in December 2014 atop the mammoth, triple barreled United Launch Alliance (ULA) Delta IV Heavy rocket, currently the most powerful booster in America’s fleet.

The Delta IV Heavy is the only rocket with sufficient thrust to launch the Orion EFT-1 capsule and its attached upper stage to its intended orbit of 3600 miles altitude above Earth – about 15 times higher than the International Space Station (ISS) and farther than any human spacecraft has journeyed in 40 years.

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

“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.”

“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.

The heat shield arrived at KSC in December 2013 loaded inside NASA’s Super Guppy aircraft while I was onsite. Read my story – here.

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 late 2017 on the EM-1 mission and more human crewed missions thereafter.

Recently, the EFT-1 launch was postponed three months from its long planned slot in mid-September to December 2014 when NASA was ordered to make way for the accelerated launch of recently declassified US Air Force Space Surveillance satellites that were given a higher priority.

The covert Geosynchronous Space Situational Awareness Program, or GSSAP, satellites were only unveiled in Feb. 2014 during a speech by General William Shelton, commander of the US Air Force Space Command.

Despite the EFT-1 launch postponement, Kennedy Space Center Director Bob Cabana said technicians are pressing forward and continue to work around the clock at KSC in order to still be ready in time to launch by the original launch window that opens in mid- September 2014.

“The contractor teams are working to get the Orion spacecraft done on time for the December 2017 launch,” said Cabana.

“They are working seven days a week in the Operations and Checkout High Bay facility to get the vehicle ready to roll out for the EFT-1 mission and be mounted on top of the Delta IV Heavy.”

“I can assure you the Orion will be ready to go on time, as soon as we get our opportunity to launch that vehicle on its first flight test and that is pretty darn amazing.”

“Our plan is to have the Orion spacecraft ready because we want to get EFT-1 out so we can start getting the hardware in for Exploration Mission-1 (EM-1) and start processing for that vehicle that will launch on the Space Launch System (SLS) rocket in 2017,” Cabana told me

Read my exclusive new interview with NASA Administrator Charles Bolden explaining the importance of getting Commercial Crew online – here.

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

Ken Kremer Delta 4 Heavy rocket and super secret US spy satellite roar off Pad 37 on June 29, 2012 from Cape Canaveral, Florida. NASA’s Orion EFT-1 capsule will blastoff atop a similar Delta 4 Heavy Booster in December 2014. Credit: Ken Kremer- kenkremer.com[/caption]

May 3, 2014December 23, 2015 by Ken Kremer

Student Designed Radiation Experiment Chosen to Soar aboard Orion EFT-1 Test Flight In Dec. 2014

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

When NASA’s next generation human spaceflight vehicle Orion blasts off on its maiden unmanned test flight later this year, a radiation experiment designed by top American high school students will soar along and play a key role in investigating how best to safeguard the health of America’s future astronauts as they venture farther into deep space than ever before – past the Moon to Asteroids, Mars and Beyond!

The student designed radiation experiment was the centerpiece of a year-long Exploration Design Challenge (EDC) competition sponsored by NASA, Orion prime contractor Lockheed Martin and the National Institute of Aerospace, and was open to high school teams across the US.

The winning experiment design came from a five-member team of High School students from the Governor’s School for Science and Technology in Hampton, Va. and was announced by NASA Administrator Charles Bolden at the opening of the 2014 U.S.A Science and Engineering Festival held in Washington, DC on April 25.

Exploration Design Challenge Winning Team NASA’s Administrator, Charles Bolden (left), President/CEO of Lockheed Martin, Marillyn Hewson (right), and astronaut Rex Walheim (back row) pose for a group photo with the winning high school team in the Exploration Design Challenge. Team ARES from the Governors School for Science and Technology in Hampton, Va. won the challenge with their radiation shield design, which will be built and flown aboard the Orion/EFT-1. The award was announced at the USA Science and Engineering Festival on April 25, 2014 at the Washington Convention Center. Credit: NASA/Aubrey Gemignani — Orion Exploration Design Challenge Winning Team from Hampton,Va
NASA’s Administrator, Charles Bolden (left), President/CEO of Lockheed Martin, Marillyn Hewson (right), and astronaut Rex Walheim (back row) pose for a group photo with the winning high school team in the Exploration Design Challenge. Team ARES from the Governors School for Science and Technology in Hampton, Va. won the challenge with their radiation shield design, which will be built and flown aboard the Orion/EFT-1. Credit: NASA/Aubrey Gemignani

The goal of the EDC competition was to build and test designs for shields to minimize radiation exposure and damaging human health effects inside NASA’s new Orion spacecraft slated to launch into orbit during the Exploration Flight Test-1 (EFT-1) pathfinding mission in December 2014. See experiment design photo herein.

This radiation shielding experiment designed by High School students from the Governor’s School for Science and Technology in Hampton, Va., was chosen as the winner of the Exploration Design Challenge contest and will fly aboard NASA’s Orion EFT-1 mission in December 2014. Credit: Lockheed Martin

During the EFT-1 flight, Orion will fly through the dense radiation field that surrounds the Earth in a protective shell of electrically charged ions – known as the Van Allen Belt – that begins 600 miles above Earth.

No humans have flown through the Van Allen Belt in more than 40 years since the Apollo era.

Team ARES from Hampton VA was chosen from a group of five finalist teams announced in March 2014.

“This is a great day for Team ARES – you have done a remarkable job,” said NASA Administrator Bolden.

“I really want to congratulate all of our finalists. You are outstanding examples of the power of American innovation. Your passion for discovery and the creative ideas you have brought forward have made us think and have helped us take a fresh look at a very challenging problem on our path to Mars.”

Since Orion EFT-1 will climb to an altitude of some 3,600 miles, the mission offers scientists the opportunity to understand how to mitigate the level of radiation exposure experienced by the astronaut crews who will be propelled to deep space destinations beginning at the end of this decade.

The student teams used a simulation tool named OLTARIS, the On- Line Tool for the Assessment of Radiation in Space, used by NASA scientists and engineers to study the effects of space radiation on shielding materials, electronics, and biological systems.

Working with mentors from NASA and Lockheed Martin, each team built prototypes and used the OLTARIS program to calculate how effective their designs – using several materials at varying thicknesses – were at shielding against radiation in the lower Van Allen belt.

“The experiment is a Tesseract Design—slightly less structurally sound than a sphere, as the stresses are located away from the cube on the phalanges. The materials and the distribution of the materials inside the tesseract were determined through research and simulation using the OLTARIS program,” Lockheed Martin spokeswoman Allison Rakes told me.

The students conducted research to determine which materials were most effective at radiation shielding to protect a dosimeter housed inside – an instrument used for measuring radiation exposure.

“The final material choices and thicknesses are (from outermost to innermost): Tantalum (.0762 cm/ .030 in), Tin (.1016 cm/ .040 in), Zirconium (.0762 cm/ .030 in), Aluminum (.0762 cm/ .030 in), and Polyethylene (9.398 cm/ 3.70 in),” according to Rakes.

At the conclusion of the EFT-1 flight, the students will use the measurement to determine how well their design protected the dosimeter.

But first Team ARES needs to get their winning proposal ready for flight. They will work with a NASA and Lockheed Martin spacecraft integration team to have the experimental design approved, assembled and installed into Orion’s crew module.

All the students hard work will pay off this December when Lockheed Martin hosts Team ARES at the Kennedy Space Center in Florida to witness the liftoff of their important experiment inside Orion atop the mammoth triple barreled Delta IV Heavy booster.

46 teams from across the country submitted engineering experiment proposals to the EDC aimed at stimulating students to work on a science, technology, engineering and math (STEM) project that tackles one of the most significant dangers of human space flight — radiation exposure.

“The Exploration Design Challenge has already reached 127,000 students worldwide – engaging them in real-world engineering challenges and igniting their imaginations about the endless possibilities of space discovery,” said Lockheed Martin Chairman, President and CEO Marillyn Hewson.

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

Ken Kremer

April 25, 2014December 23, 2015 by Ken Kremer

SpaceX CEO Elon Musk Sues Government to Break US Air Force’s National Security Launch Monopoly

SpaceX CEO Elon Musk announces lawsuit protesting Air Force launch contracts while speaking at the National Press Club in Washington, DC on April 25, 2014
Story updated[/caption]

Elon Musk, CEO and founder of the upstart commercial launch venture SpaceX, announced at a press conference today, Friday, April 25, that SpaceX is filing suit against the Federal Government to protest and break the US Air Force’s awarding of lucrative launch contracts for high priority national security satellites to a sole rocket provider – United Launch Alliance (ULA) – on a non competitive basis.

The gloves are officially off in the intensely mounting duel over multibillion dollar Air Force military launch contracts between SpaceX and ULA.

“The official protest document will be available Monday, April 28th at www.freedomtolaunch.com and will be filed with the United States Court of Federal Claims in Washington, D.C.,” said SpaceX in an official statement.

Musk said the Air Force launch contract with ULA amounted to a continuing monopoly, was unfair by blocking SpaceX from competing for launches of surveillance satellites and would cost taxpayers billions of extra dollars in coming years.

“What we feel is that this is not right – that the national security launches should be put up for competition and they should not be awarded on a sole source, uncompeted basis,” said Musk at the briefing called on short notice and held at the National Press Club in Washington, DC.

SpaceX is suing the Air Force for the right to compete for US national security satellites launches using Falcon 9 rockets such as this one which successfully launched the SES-8 communications satellite on Dec. 3, 2013 from Pad 40 at Cape Canaveral, FL. Credit: Ken Kremer/kenkremer.com

The latest Air Force launch contract dated to December 2013 guarantees the “block buy” purchase of 36 rocket cores from ULA for national security launches for the DOD, NRO and other government agencies, at a significantly reduced cost compared to earlier contracts.

A further 14 cores were to be awarded on a competitive basis, including bids from SpaceX and others who seek to gain Air Force certification. Several of those launch awards have now been deferred indefinitely.

ULA is a joint venture between aerospace giants Boeing and Lockheed Martin, formed in 2006, that has launched over 80 satellites to orbit and beyond including many NASA science and mission probes like Orion EFT-1, Curiosity, MAVEN, TDRS and more.

It manufactures the Delta IV and Atlas V unmanned, expendable rocket families that are currently the only boosters certified to launch the high value military payloads at issue in the lawsuit announced on Friday by Musk.

The newest versions of the Delta and Atlas rockets – known as EELV’s (Evolved Expendable Launch Vehicles) have had nearly flawless records of success since being introduced some dozen years ago by the companies individually, before the ULA merger.

Atlas V rocket and Super Secret NROL-67 intelligence gathering payload following rollout to Space Launch Complex 41 at Cape Canaveral Air Force Station, FL, on March 24, 2014. Credit: Ken Kremer - kenkremer.com — Atlas V rocket and Super Secret NROL-67 intelligence gathering payload following rollout to Space Launch Complex 41 at Cape Canaveral Air Force Station, FL, on March 24, 2014. Credit: Ken Kremer – kenkremer.com

Musk wants his company’s newer and he says much cheaper Falcon 9 and Falcon Heavy rockets to be certified by the Air Force and included in the competition for launch contracts.

To date the Falcon 9 has launched only 9 times. Only four of those were in the new and more powerful configuration needed by the Air Force.

Musk is not asking that the launches be awarded outright to SpaceX. But he does want the Air Force contract cancelled and re-competed.

“We’re just protesting and saying that the launches should be competed,” Musk said.

“If we compete and lose that’s fine. But why were they not even competed? That just doesn’t make sense.”

“So far we are most of the way through the certification process. And so far there have been zero changes to the rocket. Mostly it’s just been a paperwork exercise.”

“Since this is a large multiyear contract, why not wait a few months for the certification process to complete. And then do the competition. That seems very reasonable to me.”

Musk said it costs four times more to launch ULA’s Delta or Atlas rocket vs. a SpaceX Falcon rocket.

“The ULA rockets are basically four times more expensive than ours. So this contract is costing US taxpayers billions of dollars for no reason.”

“Each launch by ULA costs American taxpayers roughly $400 million per launch. They are insanely expensive. I don’t know why they are so expensive.”

The Falcon 9 lists for about $60 Million per launch, but rises to about $100 million after the certification costs are included, Musk explained.

“So yes the certification does make our Falcon 9 rocket more expensive. But not 400% more expensive.”

“Our rockets are 21st century design,” said Musk to obtain the most efficiency. He said ULA’s designs date back to the 90s and earlier with heritage hardware.

SpaceX founder and CEO Elon Musk briefs reporters including Universe Today in Cocoa Beach, FL prior to SpaceX Falcon 9 rocket blastoff with SES-8 communications satellite on Dec 3, 2013 from Cape Canaveral, FL. Credit: Ken Kremer/kenkremer.com

To date the Falcon 9 has already been used three times under a $1.6 Billion contract with NASA to launch the private SpaceX Dragon resupply vessel to the International Space Station (ISS) – most recently a week ago during the April 18 blastoff of the SpaceX CRS-3 mission from Cape Canaveral.

It is also being used to launch highly expensive communications satellites like SES-8 and Thaicom-6 for private companies to geostationary orbits.

“It just seems odd that if our vehicle is good enough for NASA and supporting a $100 billion space station, and it’s good enough for launching NASA science satellites, for launching complex commercial geostationary satellites, then there’s no reasonable basis for it not being capable of launching something quite simple like a GPS satellite,” said Musk.

“Our only option is to file a protest.”

Furthermore as I wrote here in a prior article, US National Security launches are now potentially at risk due to the ongoing crisis between Russian, Ukraine and Crimea because the RD-180 first stage engines powering the Atlas V are designed and manufactured in Russia by NPO Energomash, majority owned by the Russian Federation.

“The head of the Russian space sector, Dmitry Rogozin, was sanctioned by the White House in March 2014 in the wake of Russia’s aggression in Ukraine,” says SpaceX.

The RD-180 engine supply could be cut off in a worst case scenario if economic sanctions against Russia are increased by the Western allies.

ULA has a two year contingency supply of the RD-180’s and blueprints to begin production, if needed.

However in the event of a cutoff, it would take at least three to five years to start and certify RD-180 engine production somewhere in the US, a ULA spokesperson told me recently at Cape Canaveral.

This possibly leaves a 1 to 3 year gap with no Atlas V 1st stage engine supply.

The Delta IV rockets and engines by contrast are manufactured in the US.

“In light of international events, this seems like the wrong time to send hundreds of millions of dollars to the Kremlin,” said Musk.

“Yet, this is what the Air Force’s arrangement with ULA does, despite the fact that there are domestic alternatives available that do not rely on components from countries that pose a national security risk.”

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

Ken Kremer

March 20, 2014April 26, 2016 by Ken Kremer

NASA Unveils Orion’s Powerful Delta IV Heavy Rocket Boosters for Dec. 2014 Blastoff

CAPE CANAVERAL AIR FORCE STATION, FL – Production and assembly of virtually all of the key hardware elements for NASA’s eagerly anticipated Orion EFT-1 uncrewed test flight are either complete or nearing completion at the Kennedy Space Center and Cape Canaveral.

Two of the three first stage boosters comprising the mammoth Delta IV Heavy rocket that will propel Orion to high Earth orbit have arrived at Cape Canaveral Air Force Station, Florida, and were unveiled this week by top NASA managers at a media briefing attended by Universe Today.

The triple barreled Delta IV Heavy rocket is currently the most powerful rocket in America’s fleet and the only one capable of launching the Orion EFT-1 capsule to its intended orbit of 3600 miles altitude above Earth.

Due to urgent US national security requirements, the maiden blastoff of the unmanned Orion pathfinder capsule – that will one day send humans back to the Moon and beyond Earth’s realm – has just been postponed about three months from September to December 2014 in order to make way for the accelerated launch of recently declassified US Air Force Space Surveillance satellites – as I reported here.

The center and starboard side boosters recently arrived at the Cape aboard a barge from Decatur, Alabama where they were manufactured by United Launch Alliance (ULA).

The remaining port side booster and the Centaur upper stage are due to be shipped by ULA to Cape Canaveral in April.

“It’s great to see Orion, the next step in our journey of exploration, said NASA Associate Administrator Robert Lightfoot. “And it’s very exciting to see the engines integrated into the booster.”

“This mission is a stepping stone on NASA’s journey to Mars. The EFT-1 mission is so important to NASA. We will test the capsule with a reentry velocity of about 85% of what expect on returning [astronauts] from Mars.”

Despite the EFT-1 launch postponement, Kennedy Space Center Director Bob Cabana said technicians for prime contractor Lockheed Martin are pressing forward and continue to work around the clock at the Kennedy Space Center (KSC) in order to still be ready in time to launch by the original launch window that opens in mid- September 2014.

“The contractor teams are working to get the Orion spacecraft done on time for the December 2017 launch,” said former shuttle commander Cabana.

“They are working seven days a week in the Operations and Checkout High Bay facility to get the vehicle ready to roll out for the EFT-1 mission and be mounted on top of the Delta IV Heavy.”

“I can assure you the Orion will be ready to go on time, as soon as we get our opportunity to launch that vehicle on its first flight test and that is pretty darn amazing.”

“It’s great to see all the hardware and boosters that will take Orion to orbit.”

Universe Today also confirmed with Cabana that NASA will absolutely not delay any Orion processing and assembly activities.

Side view of two Delta IV heavy boosters powered by RS-68 engines inside Launch Complex 37 at Cape Canaveral for NASA’s upcoming Orion Exploration Flight Test-1 (EFT-1) mission. Credit: Ken Kremer - kenkremer.com — Side view of two Delta IV heavy boosters powered by RS-68 engines inside Launch Complex 37 at Cape Canaveral for NASA’s upcoming Orion Exploration Flight Test-1 (EFT-1) mission. Credit: Ken Kremer – kenkremer.com

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.

“Orion EFT-1 is really exciting as the first step on the path of humans to Mars,” said Lightfoot. It’s a stepping stone to get to Mars.”

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

Learn more at Ken’s upcoming presentations at the NEAF astro/space convention, NY on April 12/13 and at Washington Crossing State Park, NJ on April 6. Also evenings at the Quality Inn Kennedy Space Center, Titusville, FL, March 24/25 and March 29/30

Ken Kremer

March 19, 2014April 26, 2016 by Ken Kremer

US Air Force Space Surveillance Satellite Bumps NASA’s long awaited Orion Launch to Dec. 2014

Delta 4 Heavy rocket and super secret US spy satellite roar off Pad 37 on June 29, 2012 from Cape Canaveral, Florida. NASA’s Orion EFT-1 capsule will blastoff atop a similar Delta 4 Heavy Booster in December 2014. Credit: Ken Kremer- kenkremer.com
Stroy updated[/caption]

CAPE CANAVERAL AIR FORCE STATION, FL – The urgent need by the US Air Force to launch a pair of previously classified Space Situational Awareness satellites into Earth orbit this year on an accelerated schedule has bumped the inaugural blastoff of NASA’s highly anticipated Orion pathfinder manned capsule from September to December 2014.

It’s a simple case of US national security taking a higher priority over the launch of NASA’s long awaited unmanned Orion test flight on the Exploration Flight Test-1 (EFT-1) mission.

The EFT-1 flight is NASA’s first concrete step towards sending human crews on Beyond Earth Orbit (BEO) missions since the finale of the Apollo moon landing era in December 1972.

Final assembly of Orion is underway at the Kennedy Space Center (KSC).

The very existence of the covert Geosynchronous Space Situational Awareness Program, or GSSAP, was only recently declassified during a speech by General William Shelton, commander of the US Air Force Space Command.

Shelton made the announcement regarding the top secret GSSAP program during a Feb. 21 speech about the importance of space and cyberspace at the Air Force Association Air Warfare Symposium and Technology exposition, in Orlando, FL.

US national security requirements forced NASA’s Orion EFT-1 mission to swap launch slots with the GSSAP satellites – which were originally slated to launch later in 2014.

Since both spacecraft will blast off from the same pad at Complex 37 and atop Delta rockets manufactured by United Launch Alliance (ULA), a decision on priorities had to be made – and the military won out.

At a Cape Canaveral media briefing with Delta first stage boosters on Monday, March 17, Universe Today confirmed the order and payloads on the upcoming Delta IV rockets this year.

“The firing sequence for the Delta’s is the USAF Global Positioning System GPS 2F-6 [in May], GSSAP [in September] and Orion EFT-1 [in December], Tony Taliancich, ULA Director of East Coast Launch Operations, told me.

Universe Today also confirmed with the top management at KSC that NASA will absolutely not delay any Orion processing and assembly activities.

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

Despite the EFT-1 postponement, technicians for prime contractor Lockheed Martin are pressing forward and continue to work around the clock at the Kennedy Space Center (KSC) so that NASA’s Orion spacecraft can still meet the original launch window that opens in mid- September 2014 – in case of future adjustments to the launch schedule sequence.

Shelton stated that two of the GSSAP military surveillance satellites would be launched on the same launch vehicle later this year.

“GSSAP will present a significant improvement in space object surveillance, not only for better collision avoidance, but also for detecting threats,” Shelton said.

“GSSAP will bolster our ability to discern when adversaries attempt to avoid detection and to discover capabilities they may have, which might be harmful to our critical assets at these higher altitudes.”

According to a new GSSAP online fact sheet, the program will be a space-based capability operating in near-geosynchronous orbit, supporting U.S. Strategic Command space surveillance operations as a dedicated Space Surveillance Network sensor.

“Some of our most precious satellites fly in that orbit – one cheap shot against the AEHF [Advanced Extremely High Frequency] constellation would be devastating,” added Shelton. “Similarly, with our Space Based Infrared System, SBIRS, one cheap shot creates a hole in our environment. GSSAP will bolster our ability to discern when adversaries attempt to avoid detection and to discover capabilities they may have which might be harmful to our critical assets at these higher altitudes.”

GSSAP will allow more accurate tracking and characterization of man-made orbiting objects, uniquely contribute to timely and accurate orbital predictions, enhance knowledge of the geosynchronous orbit environment, and further enable space flight safety to include satellite collision avoidance.

The GSSAP satellites were covertly developed by Orbital Sciences and the Air Force.

Two additional follow on GSSAP satellites are slated for launch in 2016.

“We must be prepared as a nation to succeed in increasingly complex and contested space and cyber environments, especially in these domains where traditional deterrence theory probably doesn’t apply,” Shelton explained. “We can’t afford to wait … for that catalyzing event that will prod us to action.”

Bob Cabana, director of Kennedy Space Center, discusses Orion EFT-1 with the media at Cape Canaveral Air Force Station, FL, on March 17. Credit: Ken Kremer - kenkremer.com — Bob Cabana, director of Kennedy Space Center, discusses Orion EFT-1 with the media at Cape Canaveral Air Force Station, FL, on March 17. Credit: Ken Kremer – kenkremer.com

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

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

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

Ken Kremer

December 8, 2013December 23, 2015 by Ken Kremer

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
Story updated[/caption]

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

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

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

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

…………….

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