Kennedy Space Center Archives

August 29, 2016August 30, 2016 by Ken Kremer

NASA’s OSIRIS-REx Asteroid Sampling Probe Assembled at Florida Launch Base for Sep. 8 Blastoff — Cleanroom Photos

NASA’s OSIRIS-REx asteroid sampling spacecraft, return capsule and payload fairings inside the Payloads Hazardous Servicing Facility high bay at NASA's Kennedy Space Center is being processed for Sep. 8, 2016 launch to asteroid Bennu from Cape Canaveral, FL. Credit: Ken Kremer/kenkremer.com

NASA’s OSIRIS-Rex asteroid sampling spacecraft inside the Payloads Hazardous Servicing Facility high bay at NASA's Kennedy Space Center is being processed for Sep. 8, 2016 launch to asteroid Bennu from Cape Canaveral, FL. Credit: Ken Kremer/kenkremer.com — NASA’s OSIRIS-REx asteroid sampling spacecraft, return capsule and payload fairings inside the Payloads Hazardous Servicing Facility high bay at NASA’s Kennedy Space Center is being processed for Sep. 8, 2016 launch to asteroid Bennu from Cape Canaveral, FL. Credit: Ken Kremer/kenkremer.com

KENNEDY SPACE CENTER, FL – OSIRIS-Rex, the first American sponsored probe aimed at retrieving “pristine materials” from the surface of an asteroid and returning them to Earth has been fully assembled at its Florida launch base and is ready to blastoff ten days from today on Sep. 8. It’s a groundbreaking mission that could inform us about astrobiology and the ‘Origin of Life.’

“We are interested in that material because it is a time capsule from the earliest stages of solar system formation,” said Dante Lauretta, principal investigator for OSIRIS-REx at the University of Arizona, Tucson, in an interview with Universe Today beside the completed spacecraft inside the Payloads Hazardous Servicing Facility, or PHSF, clean room processing facility at NASA’s Kennedy Space Center in Florida.

With virtually all prelaunch processing complete, leading members of the science, engineering and launch team including Lauretta met with several members of the media, including Universe Today, inside the clean room for a last and exclusive up-close look and briefing with the one-of-its-kind $800 million Asteroid sampling probe last week.

NASA’s Origins, Spectral Interpretation, Resource Identification, Security – Regolith Explorer (OSIRIS-REx) spacecraft will launch from Space Launch Complex 41 at Cape Canaveral Air Force Station on a United Launch Alliance Atlas V rocket on September 8 at 7:05 p.m. EDT.

OSIRIS-REx goal is to fly on a roundtrip seven-year journey to the near-Earth asteroid target named Bennu and back. 101955 Bennu is a near Earth asteroid and was selected specifically because it is a carbon-rich asteroid.

While orbiting Bennu it will move in close and snatch pristine soil samples containing organic materials from the surface using the TAGSAM collection dish, and bring them back to Earth for study by researchers using all of the most sophisticated science instruments available to humankind.

“The primary objective of the OSIRIS-Rex mission is to bring back pristine material from the surface of the carbonaceous asteroid Bennu, OSIRIS-Rex Principal Investigator Dante Lauretta told Universe Today in the PHSF, as the probe was undergoing final preparation for shipment to the launch pad.

“It records the very first material that formed from the earliest stages of solar system formation. And we are really interested in the evolution of carbon during that phase. Particularly the key prebiotic molecules like amino acids, nucleic acids, phosphates and sugars that build up. These are basically the biomolecules for all of life.”

Overhead view of NASA’s OSIRIS-Rex asteroid sampling spacecraft with small white colored sample return canister atop, inside the Payloads Hazardous Servicing Facility high bay at NASA's Kennedy Space Center. Launch is slated for Sep. 8, 2016 to asteroid Bennu from Cape Canaveral Air Force Station, FL. Credit: Julian Leek — Overhead view of NASA’s OSIRIS-REx asteroid sampling spacecraft with small white colored sample return canister atop, inside the Payloads Hazardous Servicing Facility high bay at NASA’s Kennedy Space Center. Launch is slated for Sep. 8, 2016 to asteroid Bennu from Cape Canaveral Air Force Station, FL. Credit: Julian Leek

OSIRIS-REx will gather rocks and soil and bring at least a 60-gram (2.1-ounce) sample back to Earth in 2023. It has the capacity to scoop up to about 1 kg or more.

The mission will help scientists investigate how planets formed and how life began. It will also improve our understanding of asteroids that could impact Earth by measuring the Yarkovsky effect.

I asked Lauretta to explain in more detail why was Bennu selected as the target to answer fundamental questions related to the origin of life?

“We selected asteroid Bennu as the target for this mission because we feel it has the best chance of containing those pristine organic compounds from the early stage of solar system formation,” Lauretta told me.

“And that information is based on our ground based spectral characterization using telescopes here on Earth. Also, space based assets like the Hubble Space Telescope and the Spitzer Space Telescope.”

What is known about the presence of nitrogen containing compounds like amino acids and other elements on Bennu that are the building blocks of life?

“When we look at the compounds that make up these organic materials in these primitive asteroidal materials, we see a lot of carbon,” Lauretta explained.

“But we also see nitrogen, oxygen, hydrogen, sulfur and phosphorous. We call those the CHONPS. Those are the six elements we really focus on when we look at astrobiology and prebiotic chemistry and how those got into the origin of life.”

View of science instrument suite and TAGSAM robotic sample return arm on NASA’s OSIRIS-REx asteroid sampling spacecraft inside the Payloads Hazardous Servicing Facility at NASA's Kennedy Space Center. Probe is slated for Sep. 8, 2016 launch to asteroid Bennu from Cape Canaveral Air Force Station, FL. Credit: Ken Kremer/kenkremer.com — View of science instrument suite and TAGSAM robotic sample return arm on NASA’s OSIRIS-REx asteroid sampling spacecraft inside the Payloads Hazardous Servicing Facility at NASA’s Kennedy Space Center. Probe is slated for Sep. 8, 2016 launch to asteroid Bennu from Cape Canaveral Air Force Station, FL. Credit: Ken Kremer/kenkremer.com

The OSIRIS-REx spacecraft was built for NASA by prime contractor Lockheed Martin at their facility near Denver, Colorado and flown to the Kennedy Space Center on May 20.

For the past three months it has undergone final integration, processing and testing inside the PHSF under extremely strict contamination control protocols to prevent contamination by particle, aerosols and most importantly organic residues like amino acids that could confuse researchers seeking to discover those very materials in the regolith samples gathered for return to Earth.

The PHFS clean room was most recently used to process the Orbital ATK Cygnus space station resupply vehicles. It has also processed NASA interplanetary probes such as the Curiosity Mars Science Laboratory and MAVEN Mars orbiter missions.

Side view of NASA’s OSIRIS-Rex asteroid sampling spacecraft showing the High Gain Antenna at left and solar panel, inside the Payloads Hazardous Servicing Facility high bay at NASA's Kennedy Space Center. Probe is being processed for Sep. 8, 2016 launch to asteroid Bennu from Cape Canaveral Air Force Station, FL. Credit: Ken Kremer/kenkremer.com — Side view of NASA’s OSIRIS-REx asteroid sampling spacecraft showing the High Gain Antenna at left and solar panel, inside the Payloads Hazardous Servicing Facility high bay at NASA’s Kennedy Space Center. Probe is being processed for Sep. 8, 2016 launch to asteroid Bennu from Cape Canaveral Air Force Station, FL. Credit: Ken Kremer/kenkremer.com

The spacecraft will reach Bennu in 2018. Once within three miles (5 km) of the asteroid, the spacecraft will begin at least six months of comprehensive surface mapping of the carbonaceous asteroid, according to Heather Enos, deputy principal investigator, in an interview with Universe Today.

“We will then move the spacecraft to within about a half kilometer or so to collect further data,” Enos elaborated.

It will map the chemistry and mineralogy of the primitive carbonaceous asteroid. The team will initially select about 10 target areas for further scrutiny as the sampling target. This will be whittled down to two, a primary and backup, Enos told me.

After analyzing the data returned, the science team then will select a site where the spacecraft’s robotic sampling arm will grab a sample of regolith and rocks. The regolith may record the earliest history of our solar system.

Engineers will command the spacecraft to gradually move on closer to the chosen sample site, and then extend the arm to snatch the pristine samples the TAGSAM sample return arm.

PI Lauretta will make the final decision on when and which site to grab the sample from.

“As the Principal Investigator for the mission I have responsibility for all of the key decisions during our operations,” Lauretta replied. “So we will be deciding on where we want to target our high resolution investigations for sample site evaluation. And ultimately what is the one location we want to send the spacecraft down to the surface of the asteroid to and collect that sample.”

“And then we have to decide like if we collected enough sample and are we ready to stow it in the sample return capsule. Or are we going to use one of our 2 contingency bottles of gas to go for a second attempt.”

“The primary objective is one successful sampling event. So when we collect 60 grams or 2 ounces of sample then we are done!”

“In the event that we decide to collect more, it will be intermixed with anything we collected on the first attempt.”

The priceless sample will then be stowed in the on board sample return capsule for the long journey back to Earth.

NASA’s OSIRIS-Rex asteroid sampling spacecraft inside the Payloads Hazardous Servicing Facility high bay at NASA's Kennedy Space Center. Launch is slated for Sep. 8, 2016 to asteroid Bennu from Cape Canaveral Air Force Station, FL. Credit: Lane Hermann — NASA’s OSIRIS-Rex asteroid sampling spacecraft inside the Payloads Hazardous Servicing Facility high bay at NASA’s Kennedy Space Center. Launch is slated for Sep. 8, 2016 to asteroid Bennu from Cape Canaveral Air Force Station, FL. Credit: Lane Hermann

Bennu is an unchanged remnant from the collapse of the solar nebula and birth of our solar system some 4.5 billion years ago, little altered over time.

Bennu is a near-Earth asteroid and was selected for the sample return mission because it could hold clues to the origin of the solar system and host organic molecules that may have seeded life on Earth.

Artist’s conception of NASA’s OSIRIS-REx spacecraft at Bennu. Credits: NASA/GSFC

OSIRIS-REx will return the largest sample from space since the American and Soviet Union’s moon landing missions of the 1970s.

Watch this USLaunchReport video shot during media visit inside the PHSF on Aug. 20, 2016:

Video caption: Our first introduction to the OSIRIS-REx asteroid bound mission in search of the origins of life, from inside the Payloads Hazardous Servicing Facility at NASA’s Kennedy Space Center on Aug. 20, 2016. Credit: USLaunchReport

OSIRIS-REx is the third mission in NASA’s New Frontiers Program, following New Horizons to Pluto and Juno to Jupiter, which also launched on Atlas V rockets.

NASA’s Goddard Space Flight Center in Greenbelt, Maryland, is responsible for overall mission management.

OSIRIS-REx complements NASA’s Asteroid Initiative – including the Asteroid Redirect Mission (ARM) which is a robotic spacecraft mission aimed at capturing a surface boulder from a different near-Earth asteroid and moving it into a stable lunar orbit for eventual up close sample collection by astronauts launched in NASA’s new Orion spacecraft. Orion will launch atop NASA’s new SLS heavy lift booster concurrently under development.

Watch for Ken’s continuing OSIRIS-REx mission and launch reporting from on site at the Kennedy Space Center and Cape Canaveral Ait Force Station, FL.

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

Ken Kremer

The University of Arizona’s camera suite, OCAMS, sits on a test bench that mimics its arrangement on the OSIRIS-REx spacecraft. The three cameras that compose the instrument – MapCam (left), PolyCam and SamCam – are the eyes of NASA’s OSIRIS-REx mission. They will map the asteroid Bennu, help choose a sample site, and ensure that the sample is correctly stowed on the spacecraft. Credits: University of Arizona/Symeon Platts

August 26, 2016August 26, 2016 by Ken Kremer

SpaceX Dragon Splashes Down with NASA’s Station Science Cargo

SpaceX Dragon CRS-9 returned to Earth with a splash down in the Pacific Ocean on Friday, Aug. 26, 2016 after more than a month stay at the International Space Station. Credit: SpaceX

A SpaceX commercial Dragon cargo ship returned to Earth today, Friday, Aug. 26, 2016, by splashing down safely in the Pacific Ocean – thus concluding more than a month long stay at the International Space Station (ISS). The vessel was jam packed with some 1.5 tons of NASA cargo and critical science samples for eagerly waiting researchers.

The parachute assisted splashdown of the Dragon CRS-9 cargo freighter took place at 11:47 a.m. EDT today in the Pacific Ocean – located some 326 miles (520 kilometers) southwest of Baja California.

Dragon departed after spending more than five weeks berthed at the ISS.

This image, captured from NASA Television's live coverage, shows SpaceX's Dragon spacecraft departing the International Space Station at 6:10 am EDT Friday, Aug. 26, 2016, after successfully delivering almost 5,000 pounds of supplies and scientific cargo on its ninth resupply mission to the orbiting laboratory. Credits: NASA Television — This image, captured from NASA Television’s live coverage, shows SpaceX’s Dragon spacecraft departing the International Space Station at 6:10 am EDT Friday, Aug. 26, 2016, after successfully delivering almost 5,000 pounds of supplies and scientific cargo on its ninth resupply mission to the orbiting laboratory. Credits: NASA Television

It was loaded with more than 3,000 pounds of NASA cargo and critical research samples and technology demonstration samples accumulated by the rotating six person crews of astronauts and cosmonauts living and working aboard the orbiting research laboratory.

This station based research will contribute towards NASA’s strategic plans to send astronauts on a ‘Journey to Mars’ by the 2030s.

It arrived at the station on July 20 ferrying over 2.5 tons of priceless research equipment, gear, spare parts and supplies, food, water and clothing for the station’s resident astronauts and cosmonauts as well as the first of two international docking adapters (IDAs) in its unpressurized cargo hold known as the “trunk.”

The SpaceX Dragon is captured in the grips of the Canadarm2 robotic arm. Credit: NASA TV

Dragon was launched on July 18 during a mesmerizing post midnight, back-to-back liftoff and landing of the SpaceX Falcon 9 rocket in its upgraded, full thrust version.

SpaceX Falcon 9 launches and lands over Port Canaveral in this streak shot showing rockets midnight liftoff from Space Launch Complex 40 at Cape Canaveral Air Force Station in Florida at 12:45 a.m. EDT on July 18, 2016 carrying Dragon CRS-9 craft to the International Space Station (ISS) with almost 5,000 pounds of cargo and docking port. View from atop Exploration Tower in Port Canaveral. Credit: Ken Kremer/kenkremer.com

The SpaceX Falcon 9 blasted off at 12:45 a.m. EDT July 18, from Space Launch Complex 40 at Cape Canaveral Air Force Station in Florida and successfully delivered the Dragon CRS-9 resupply ship to its preliminary orbit about 10 minutes later.

SpaceX also successfully executed a spellbinding ground landing of the Falcon 9 first stage back at Cape Canaveral Air Force Station’s Landing Zone 1, located a few miles south of launch pad 40.

The dramatic ground landing of the 156 foot tall Falcon 9 first stage at LZ -1 took place about 9 minutes after liftoff. It marked only the second time a spent, orbit class booster has touched down intact and upright on land.

Moments before dramatic touchdown of SpaceX Falcon 9 1st stage at Landing Zone-1 (LX-1) accompanied by sonic booms after launching Dragon CRS-9 supply ship to orbit from Cape Canaveral Air Force Station, Florida at 12:45 a.m., bound for the International Space Station (ISS). Credit: Ken Kremer/kenkremer.com

The stage was set for today’s return to Earth when ground controllers robotically detached Dragon from the Earth-facing port of the Harmony module early this morning using the station’s 57.7-foot (17.6-meter) long Canadian-built robotic arm.

Expedition 48 Flight Engineers Kate Rubins of NASA and Takuya Onishi of the Japan Aerospace Exploration Agency (JAXA) then used Canadarm 2 to release Dragon from the grappling snares at about 6:10 a.m. EDT (1011 GMT) this morning.

“Houston, station, on Space to Ground Two, Dragon depart successfully commanded,” radioed Rubins.

The ISS was soaring some 250 miles over the Timor Sea, north of Australia.

“Congratulations to the entire team on the successful release of the Dragon. And thank you very much for bringing all the science, and all the important payloads, and all the important cargo to the station,” Onishi said. “We feel really sad to see it go because we had a great time and enjoyed working on all the science that the Dragon brought to us.”

Dragon then backed away and moved to a safe distance from the station via a trio of burns using its Draco maneuvering thrusters.

The de-orbit burn was conducted at 10:56 a.m. EDT (1456 GMT) to drop Dragon out of orbit and start the descent back to Earth.

SpaceX contracted recovery crews hauled Dragon aboard the recovery ship and are transporting it to a port near Los Angeles, where some time critical cargo items and research samples will be removed and returned to NASA for immediate processing.

SpaceX plans to move Dragon back to the firms test facility in McGregor, Texas, for further processing and to remove the remaining cargo cache.

Among the wealth of over 3900 pounds (1790 kg) of research investigations loaded on board Dragon was an off the shelf instrument designed to perform the first-ever DNA sequencing in space and the first international docking adapter (IDA) that is absolutely essential for docking of the SpaceX and Boeing built human spaceflight taxis that will ferry our astronauts to the International Space Station (ISS) in some 18 months.

During a spacewalk last week on Aug. 19, the initial docking adapter known as International Docking Adapter-2 (IDA-2) was installed Expedition 48 Commander Jeff Williams and Flight Engineer Kate Rubins of NASA.

Other science experiments on board included OsteoOmics to test if magnetic levitation can accurately simulate microgravity to study different types of bone cells and contribute to treatments for diseases like osteoporosis, a Phase Change Heat Exchanger to test temperature control technology in space, the Heart Cells experiments that will culture heart cells on the station to study how microgravity changes the human heart, new and more efficient three-dimensional solar cells, and new marine vessel tracking hardware known as the Automatic Identification System (AIS) that will aid in locating and identifying commercial ships across the globe.

The ring shaped IDA-2 unit was stowed in the Dragon’s unpressurized truck section. It weighs 1029 lbs (467 kg), measures about 42 inches tall and sports an inside diameter of 63 inches in diameter – so astronauts and cargo can easily float through. The outer diameter measures about 94 inches.

“Outfitted with a host of sensors and systems, the adapter is built so spacecraft systems can automatically perform all the steps of rendezvous and dock with the station without input from the astronauts. Manual backup systems will be in place on the spacecraft to allow the crew to take over steering duties, if needed,” says NASA.

“It’s a passive system which means it doesn’t take any action by the crew to allow docking to happen and I think that’s really the key,” said David Clemen Boeing’s director of Development/Modifications for the space station.

“Spacecraft flying to the station will use the sensors on the IDA to track to and help the spacecraft’s navigation system steer the spacecraft to a safe docking without astronaut involvement.”

CRS-9 counts as the company’s ninth of 26 scheduled flight to deliver supplies, science experiments and technology demonstrations to the International Space Station (ISS).

The CRS-9 mission was launched for the crews of Expeditions 48 and 49 to support dozens of the approximately 250 science and research investigations in progress under NASA’s Commercial Resupply Services (CRS) contract.

Watch for Ken’s continuing SpaceX and CRS mission coverage where he reported onsite direct from the Kennedy Space Center and Cape Canaveral Air Force Station, Florida.

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

Ken Kremer

An illustration of how the IDA will look when attached to the International Space Station. Credits: NASA — An illustration of how the IDA will look when attached to the International Space Station.
Credits: NASA

Up close view of SpaceX Dragon CRS-9 resupply ship and solar panels atop Falcon 9 rocket at pad 40 prior to blastoff to the ISS on July 18, 2016 from Cape Canaveral Air Force Station, Florida. Credit: Ken Kremer/kenkremer.com

View of International Docking Adapter 2 (IDA-2) being processed inside the Space Station Processing Facility (SSPF) at NASA Kennedy Space Center for eventual launch to the ISS in the trunk of a SpaceX Dragon on the CRS-9 mission. It will be connected to the station to provide a port for Commercial Crew spacecraft carrying astronauts to dock to the orbiting laboratory as soon as 2017. The identical IDA-1 was destroyed during SpaceX CRS-7 launch failure on June 28, 2015. Credit: Ken Kremer/kenkremer.com

August 20, 2016August 22, 2016 by Ken Kremer

NASA Successfully Test Fires Mars Mega Rocket Engine with Modernized ‘Brain’ Controller

NASA engineers successfully conducted a development test of the RS-25 rocket engine Thursday, Aug. 18, 2016 at NASA’s Stennis Space Center near Bay St. Louis, Miss. The RS-25 will help power the core stage of the agency’s new Space Launch System (SLS) rocket for the journey to Mars. Credit: Ken Kremer/kenkremer.com

NASA engineers successfully conducted a development test of the RS-25 rocket engine Thursday, Aug. 18 at NASA’s Stennis Space Center near Bay St. Louis, Miss. The RS-25 will help power the core stage of the agency’s new Space Launch System (SLS) rocket for the journey to Mars. Credit: Ken Kremer/kenkremer.com

NASA STENNIS SPACE CENTER, MISS – NASA engineers successfully carried out a key developmental test firing of an RS-25 rocket engine along with its modernized ‘brain’ controller at the Stennis Space Center on Thursday, Aug. 18, as part of the ongoing huge development effort coordinating the agency’s SLS Mars mega rocket slated for its maiden blastoff by late 2018.

“Today’s test was very successful,” Steve Wofford, manager of the SLS Liquid Engines Office at NASA’s Marshall Space Flight Center in Huntsville, Alabama, told Universe Today in an exclusive interview at the conclusion of the exciting RS-25 engine test gushing a huge miles long plume of steam at NASA Stennis on Aug. 18 under sweltering Gulf Coast heat.

“It was absolutely great!”

Thursday’s full thrust RS-25 engine hot fire test, using engine No. 0528, ran for its planned full duration of 7.5 minutes and met a host of critical test objectives required to confirm and scope out the capabilities and operating margins of the upgraded engines ,which are recycled from the shuttle era.

“We ran a full program duration of 420 seconds . And we had no failure identifications pop up.”

“It looks like we achieved all of our data objectives,” Wofford elaborated to Universe Today, after we witnessed the test from a viewing area just a few hundred meters away, with our ears protected by ear plugs.

A cluster of four RS-25 engines will power the Space Launch System (SLS) at the base of the first stage, also known as the core stage.

Huge plume of steam gushes as NASA engineers successfully conducted a development test of the RS-25 rocket engine Thursday, Aug. 18 at NASA’s Stennis Space Center near Bay St. Louis, Miss., in this panoramic view. The RS-25 will help power the core stage of the agency’s new Space Launch System (SLS) rocket for the journey to Mars. Credit: Ken Kremer/kenkremer.com

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 – venturing further out than humans ever have before!

NASA’s goal is to send humans to Mars by the 2030s with SLS and Orion.

Ignition of the RS-25 engine creates a huge plume of steam gushing out the test stand during successful hot fire development test on Thursday, Aug. 18 at NASA’s Stennis Space Center near Bay St. Louis, Miss., in this panoramic view. The RS-25 will help power the core stage of the agency’s new Space Launch System (SLS) rocket for the journey to Mars. Credit: Ken Kremer/kenkremer.com

The primary goal of the development tests is to validate the capabilities of a new controller – or, “brain” – for the engine and to verify the different operating conditions needed for the SLS vehicle.

The test was part of a long continuing and new series aimed at certifying the engines for flight.

“We continue this test series in the fall. Which is a continuing part of our certification series to fly these engines on NASA’s SLS vehicle,” Wofford told me.

What was the primary objective of today’s test?

“Today’s test was mostly about wringing out the new control system. We have a new engine controller on this engine. And we have to certify that new controller for flight.”

“So to certify it we run it through its paces in ground tests. And we put it through a more stringent set of test conditions than it will ever see in flight.”

“The objectives we tested today required 420 seconds of testing to complete.”

Watch this NASA video of the full test:

Video Caption: RS-25 Rocket Engine Test Firing on 18 Aug. 2016: The 7.5-minute test conducted at NASA’s Stennis Space Center is part of a series of tests designed to put the upgraded former space shuttle engines through the rigorous temperature and pressure conditions they will experience during a launch of NASA’s Space Launch System mega rocket. Credit: NASA

What are the additional objectives from today’s test?

“Well you can’t do all of your objectives in one test. So the certification series are all about technical objectives and total accumulated time. So one thing we did was we accumulated time toward the time we need to certify this control system for the SLS engine,” Wofford explained.

“The other thing we did was you pick some technical objectives you want to put the controller through its paces for. And again you can’t do all of those in one test. So you spread them over a series. And we did some of those on this test.”

Aerojet Rocketdyne is the prime contractor for the RS-25 engine work and originally built them during the shuttle era.

The remaining cache of 16 heritage RS-25 engines are being recycled from their previous use as reusable space shuttle main engines (SSMEs). They are now being refurbished, upgraded and tested by NASA and Aerojet Rocketdyne to power the core stage of the Space Launch System rocket now under full development.

During launch they will fire at 109 percent thrust level for some eight and a half minutes while generating a combined two million pounds of thrust.

The SLS core stage is augmented with a pair of five segment solid rocket boosters (SRBs) generating about 3.3 million pounds of thrust each. NASA and Orbital just completed the QM-2 SRB qualification test on June 28.

Each of the RS-25’s engines generates some 500,000 pounds of thrust. They are fueled by cryogenic liquid hydrogen (LH2) and liquid oxygen (LOX).

The first liquid hydrogen (LH2) qualification fuel tank for the core stage was just welded together at NASA’s Michoud Assembly Facility in New Orleans – as I witnessed exclusively and reported here.

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 — 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

The RS-25 engines measure 14 feet tall and 8 feet in diameter.

For SLS they will be operating at 109% of power – a higher power level compared to a routine usage of 104.5% during the shuttle era.

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

Why was about five seconds of Thursday’s test run at the 111% power level? Will that continue in future tests?

“We did that because we plan to fly this engine on SLS at 109% of power level. So it’s to demonstrate the feasibility of doing that. On shuttle we were certified to fly these engines at 109%,” Wofford confirmed to Universe Today.

“So to demonstrate the feasibility of doing 109% power level on SLS we ‘overtest’ . So we ran [today’s test] at 2 % above where we are going to fly in flight.”

“We will do more in the future.”

The fully assembled core stage intergrated with all 4 RS-25 flight engines will be tested at the B-2 test stand in Stennis during the first quarter of 2018 – some 6 months or more before the launch in late 2018.

How many more engines tests will be conducted prior to the core stage test?

“After today we will run 7 more tests before the core stage test and the first flight.”

“I’m thrilled. I’ve see a lot of these and it never gets old!” Wofford gushed.

The hardware for SLS and Orion is really coming together now and its becoming more and more real every day.

Orion crew module pressure vessel for NASA’s Exploration Mission-1 (EM-1) is unveiled for the first time on Feb. 3, 2016 after arrival at the agency’s Kennedy Space Center (KSC) in Florida. It is secured for processing in a test stand called the birdcage in the high bay inside the Neil Armstrong Operations and Checkout (O&C) Building at KSC. Launch to the Moon is slated in 2018 atop the SLS rocket. Credit: Ken Kremer/kenkremer.com

These are exciting times for NASA’s human deep space exploration strategy.

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) Block 1 configuration with a liftoff thrust of 8.4 million pounds – more powerful than NASA’s Saturn V moon landing rocket.

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.

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

Ken Kremer

August 17, 2016August 17, 2016 by Ken Kremer

Stairway to Heaven! – Boeing Starliner Crew Access Arm’s ‘Awesome’ Launch Pad Installation

A crane lifts the Crew Access Arm and White Room for Boeing's CST-100 Starliner spacecraft for mating to the Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41 on Aug. 15, 2016. Astronauts will walk through the arm to board the Starliner spacecraft stacked atop a United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com

CAPE CANAVERAL AIR FORCE STATION, FL — A new ‘Stairway to Heaven’ which American astronauts will soon stride along as “the last place on Earth” departure point aboard our next generation of human spaceships, was at long last hoisted into place at the ULA Atlas rocket launch pad on Florida’s Space Coast on Monday Aug 15, at an “awesome” media event witnessed by space journalists including Universe Today.

“This is awesome,” Chris Ferguson, a former shuttle commander who is now Boeing’s deputy program manager for the company’s Commercial Crew Program told Universe Today in an exclusive interview at the launch pad – after workers finished installing the spanking new Crew Access Arm walkway for astronauts leading to the hatch of Boeing’s Starliner ‘Space Taxi.’

Starliner will ferry crews to and from the International Space Station (ISS) as soon as 2018.

“It’s great to see the arm up there,” Ferguson elaborated to Universe Today. “I know it’s probably a small part of the overall access tower. But it’s the most significant part!”

“We used to joke about the 195 foot level on the shuttle pad as being ‘the last place on Earth.”

“This will now be the new ‘last place on Earth’! So we are pretty charged up about it!” Ferguson gushed.

Up close view of Boeing Starliner Crew Access Arm and White Room craned into place at Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41 on Aug. 15, 2016. Credit: Dawn Leek Taylor

Under hot sunny skies portending the upcoming restoration of America’s ability to once again launch American astronauts from American soil when American rockets ignite, the newly constructed 50-foot-long, 90,000-pound ‘Crew Access Arm and White Room’ was lifted and mated to the newly built ‘Crew Access Tower’ at Space Launch Complex-41 (SLC-41) on Monday morning, Aug. 15.

“We talked about how the skyline is changing here and this is one of the more visible changes.”

The Boeing CST-100 Starliner crew capsule stacked atop the venerable United Launch Alliance (ULA) Atlas V rocket at pad 41 on Cape Canaveral Air Force Station in Florida will launch crews to the massive orbiting science outpost continuously soaring some 250 miles (400 km) above Earth.

Space workers, enthusiasts and dreamers alike have been waiting years for this momentous day to happen. And I was thrilled to observe all the action firsthand along with the people who made it happen from NASA, United Launch Alliance, Boeing, the contractors – as well as to experience it with my space media colleagues.

“All the elements that we talked about the last few years are now reality,” Ferguson told me.

The Crew Access Arm and White Room for Boeing's CST-100 Starliner spacecraft approaches the notch for mating to the Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41 at level 13 on Aug. 15, 2016, as workers observe from upper tower level. Astronauts will walk through the arm to board the Starliner spacecraft stacked atop a United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com — The Crew Access Arm and White Room for Boeing’s CST-100 Starliner spacecraft approaches the notch for mating to the Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41 at level 13 on Aug. 15, 2016, as workers observe from upper tower level. Astronauts will walk through the arm to board the Starliner spacecraft stacked atop a United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com

Attaching the access arm is vital and visual proof that at long last America means business and that a renaissance in human spaceflight will commence in some 18 months or less when commercially built American crew capsules from Boeing and SpaceX take flight to the heavens above – and a new space era of regular, robust and lower cost space flights begins.

It took about an hour for workers to delicately hoist the gleaming grey steel and aluminum white ‘Stairway to Heaven’ by crane into place at the top of the tower – at one of the busiest launch pads in the world!

It’s about 130 feet above the pad surface since it’s located at the 13th level of the tower.

The install work began at about 7:30 a.m. EDT as we watched a work crew lower a giant grappling hook and attach cables. Then they carefully raised the arm off the launch pad surface by crane. The arm had been trucked to the launch pad on Aug. 11.

The tower itself is comprised of segmented tiers that were built in segments just south of the pad. They were stacked on the pad over the past few months – in between launches. Altogether they form a nearly 200-foot-tall steel structure.

Another crew stationed in the tower about 160 feet above ground waited as the arm was delicately craned into the designated notch. The workers then spent several more hours methodically bolting and welding the arm to the tower to finish the assembly process.

Indeed Monday’s installation of the Crew Access Arm and White Room at pad 41 basically completes the construction of the first new Crew Access Tower at Cape Canaveral Air Force Station since the Apollo moon landing era of the 1960s.

“It is the first new crew access structure at the Florida spaceport since the space shuttle’s Fixed Service Structures were put in place before Columbia’s first flight in 1981,” say NASA officials.

Overall the steel frame of the massive tower weighs over a million pounds. For perspective, destination ISS now weighs in at about a million pounds in low Earth orbit.

Construction of the tower began about 18 months ago.

“You think about when we started building this 18 months ago and now it’s one of the most visible changes to the Cape’s horizon since the 1960s,” said Ferguson at Monday’s momentous media event. “It’s a fantastic day.”

The White Room is an enclosed area at the end of the Crew Access Arm. It big enough for astronauts to make final adjustments to their suits and is spacious enough for technicians to assist the astronauts climbing aboard the spacecraft and get tucked into their seats in the final hours before liftoff.

“You have to stop and celebrate these moments in the craziness of all the things we do,” said Kathy Lueders, manager of NASA’s Commercial Crew Program, at the event. “It’s going to be so cool when our astronauts are walking out across this access arm to get on the spacecraft and go to the space station.”

The Crew Access Arm was built by Saur at NASA’s nearby off site facility at Oak Hill.

And when Starliner takes flight it will hearken back to the dawn of the Space Age.

“John Glenn was the first to fly on an Atlas, now our next leap into the future will be to have astronauts launch from here on Atlas V,” said Barb Egan, program manager for Commercial Crew for ULA.

Boeing is manufacturing Starliner in what is officially known as Boeing’s Commercial Crew and Cargo Processing Facility (C3PF) at the Kennedy Space Center in Florida under contract with NASA’s Commercial Crew Program (CCP).

Hull of the Boeing CST-100 Starliner Structural Test Article (STA)- the first Starliner to be built in the company’s modernized Commercial Crew and Cargo Processing Facility high bay at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com

The Boeing CST 100 Starliner is one of two private astronaut capsules – along with the SpaceX Crew Dragon – being developed under a CCP commercial partnership contract with NASA to end our sole reliance on Russia for crew launches back and forth to the International Space Station (ISS).

The goal of NASA’s Commercial Crew Program since its inception in 2010 is to restore America’s capability to launch American astronauts on American rockets from American soil to the ISS, as soon as possible.

Furthermore when the Boeing Starliner and SpaceX Crew Dragon become operational the permanent resident ISS crew will grow to 7 – enabling a doubling of science output aboard the science laboratory.

This significant growth in research capabilities will invaluably assist NASA in testing technologies and human endurance in its agency wide goal of sending humans on a ‘Journey to Mars’ by the 2030s with the mammoth Space Launch System (SLS) rocket and Orion deep space capsule concurrently under full scale development by the agency.

The next key SLS milestone is a trest firing of the RS-25 main engines at NASA Stennis this Thursday, Aug. 18 – watch for my onsite reports!

Boeing was awarded a $4.2 Billion contract in September 2014 by NASA Administrator Charles Bolden to complete development and manufacture of the CST-100 Starliner space taxi under the agency’s Commercial Crew Transportation Capability (CCtCap) program and NASA’s Launch America initiative.

Since the retirement of NASA’s space shuttle program in 2011, the US was been 100% dependent on the Russian Soyuz capsule for astronauts rides to the ISS at a cost exceeding $70 million per seat.

When will Ferguson actually set foot inside the walkway?

“I am hoping to get up there and walk through there in a couple of weeks or so when it’s all strapped in and done. I want to see how they are doing and walk around.”

How does the White Room fit around Starliner and keep it climate controlled?

“The end of the white room has a part that slides up and down and moves over and slides on top of the spacecraft when it’s in place.”

“There is an inflatable seal that forms the final seal to the spacecraft so that you have all the appropriate humidity control and the purge without the Florida atmosphere inside the crew module,” Ferguson replied.

Up close, mid-air view of Crew Access Tower and front of White Room during installation. The White Room will fit snugly against Boeing's CST-100 Starliner spacecraft with inflatable seal to maintain climate control and clean conditions as astronauts board capsule atop Atlas rocket hours before launch on United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com — Up close, mid-air view of Crew Access Arm and front of White Room during installation. The White Room will fit snugly against Boeing’s CST-100 Starliner spacecraft with inflatable seal to maintain climate control and clean conditions as astronauts board capsule atop Atlas rocket hours before launch on United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com

Boeing and NASA are targeting Feb. 2018 for launch of the first crewed orbital test flight on the Atlas V rocket. The Atlas will be augmented with two solid rocket motors on the first stage and a dual engine Centaur upper stage.

How confident is Ferguson about meeting the 2018 launch target?

“The first crew flight is scheduled for February 2018. I am confident.” Ferguson responded.

“And we have a lot of qualification to get through between now and then. But barring any large unforeseen issues we can make it.”

The Crew Access Tower after installation of the Crew Access Arm and White Room for Boeing's CST-100 Starliner spacecraft on Aug. 15, 2016 at Space Launch Complex 41 on Cape Canaveral Air Force Station, Fl. Credit: Ken Kremer/kenkremer.com — The Crew Access Tower after installation of the Crew Access Arm and White Room for Boeing’s CST-100 Starliner spacecraft on Aug. 15, 2016 at Space Launch Complex 41 on Cape Canaveral Air Force Station, Fl. Credit: Ken Kremer/kenkremer.com

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

Ken Kremer

As the Boeing Starliner Crew Access Arm and White Room are bolted into place behind us at Space Launch Complex 41, Chris Ferguson, former shuttle commander and current Boeing deputy program manager for Commercial Crew, and Ken Kremer of Universe Today discuss the details and future of human spaceflight on Aug. 15, 2016 at Cape Canaveral Air Force Station. Credit: Jeff Seibert — As the Boeing Starliner Crew Access Arm and White Room are bolted into place behind us at Space Launch Complex 41, Chris Ferguson, former shuttle commander and current Boeing deputy program manager for Commercial Crew, and Ken Kremer of Universe Today discuss the future of human spaceflight on Aug. 15, 2016 at Cape Canaveral Air Force Station. Credit: Jeff Seibert

August 7, 2016August 8, 2016 by Ken Kremer

Boeing Starts Assembly of 1st Flightworthy Starliner Crew Taxi Vehicle at Kennedy Spaceport

KENNEDY SPACE CENTER, FL – The next generation of America’s human spaceships is rapidly taking shape and “making fantastic progress” at the Kennedy Space Center as Boeing and NASA showcased the start of assembly of the first flightworthy version of the aerospace giants Starliner crew taxi vehicle to the media last week. Starliner will ferry NASA astronauts to and from the International Space Station (ISS) by early 2018.

“We are making fantastic progress across the board,” John Mulholland, vice president and program manager of Boeing Commercial Programs, told Universe Today at the July 26 media event in Boeing’s new Starliner factory.

“It so nice to move from design to firm configuration, which was an incredibly important milestone, to now moving into the integrated qual phase of the campaign.”

Boeing is swiftly making tangible progress towards once again flying Americans astronauts to space from American soil as was quite visibly demonstrated when the firm showed off their spanking new Starliner ‘clean-floor factory’ to the media last week, including Universe Today – and it’s already humming with activity by simultaneously building two full scale Starliner crew vehicles.

“We are on track to support launch by the end of 2017 [of the uncrewed orbital test flight],” Mulholland told me.

“The Structural Test Article (STA) crew module is almost ready to be delivered to the test site in California. The service module is already delivered at the test site. So we are ready to move into the qualification campaign.”

“We are also in the middle of component qualification and qualifying more than one component every week as we really progress into assembly, integration and test of flight design spacecrafts.”

Starliner is being manufactured in what is officially known as Boeing’s Commercial Crew and Cargo Processing Facility (C3PF) at the Kennedy Space Center in Florida under contract with NASA’s Commercial Crew Program (CCP).

And the Boeing CST-100 Starliner assembly line aiming to send our astronauts to low Earth orbit and the space station is now operating full speed ahead at KSC.

Formerly known as Orbiter Processing Facility-3, or OPF-3, the facility was previously used as a servicing hanger to prepare NASA’s space shuttle orbiters for flight.

NASA-Boeing Mentor NASA, industry and news media representatives visit the modernized high bay in Boeing's Commercial Crew and Cargo Processing Facility at NASA’s Kennedy Space Center in Florida. Credits: NASA/Kim Shiflett — NASA, industry and news media representatives visit the modernized high bay in Boeing’s Commercial Crew and Cargo Processing Facility at NASA’s Kennedy Space Center in Florida. Credits: NASA/Kim Shiflett

The facility has now been completely renovated and refurbished by removing about 11,000 tons of massive steel work platforms that once enshrouded the space shuttle orbiters for servicing and refurbishment for flight – and been transformed into Boeings gleaming white C3PF Starliner manufacturing facility.

Components for the first Starliner that will actually fly in space – known as Spacecraft 1 – began arriving recently at the C3PF. These include the upper and lower domes, as well as the docking hatch for the spacecrafts pressure vessel.

“You can see the beginning of Spacecraft 1. To build it all of the major structural elements are here,” Mulholland explained.

“The lower dome will be populated and get to first power on early next year. We are really looking forward to that. Then we will mate that to the upper dome and start in on the ground qualification on Spacecraft 1.”

Altogether Boeing is fabricating three Starliner flight spacecraft.

“We will start building Spacecraft 2 in the Fall of this year. And then we will start Spacecraft 3 early next year.”

“So we will have three Starliner spacecraft flight crew module builds as we move into the flight campaign.”

The honeycombed upper dome of a Boeing Starliner spacecraft on a work stand inside the company’s Commercial Crew and Cargo Processing Facility at NASA’s Kennedy Space Center in Florida. The upper dome is part of Spacecraft 1 , the first flightworthy Starliner being developed in partnership with NASA’s Commercial Crew Program. Credit: Ken Kremer/kenkremer.com

Technicians are outfitting these individual components of the pressure vessel with wiring and lines, avionics and other systems, before they are bolted together.

Spacecraft 1 is actually the second Starliner being manufactured at the Kennedy Space Center.

The first full scale Starliner vehicle to be built is known as the Structural Test Article (STA) and is nearing completion.

The lower dome of the Boeing Starliner Spacecraft 1 assembly being outfitted with flight systems like wiring, lines, avionics in the firm’s Commercial Crew and Cargo Processing Facility high bay at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com

Notably Spacecraft 1 will be the first Starliner to fly in the company’s pad abort test.

“Spacecraft 1 will go into the ground campaign and then the pad abort,” Mulholland stated.

“The test is designed to prove the launch abort system planned for the spacecraft will be able to lift astronauts away from danger in the event of an emergency during launch operations,” says NASA.

The Pad Abort test is currently slated for October 2017 in New Mexico. Boeing will fly an uncrewed orbital flight test in December 2017 and a crewed orbital flight test in February 2018.

“Spacecraft 3 will be the first to fly in orbit on the uncrewed flight test by the end of 2017,” Mulholland confirmed.

‘Spacecraft 2 will go through a several month long thermal vac testing and EMI and EMC in California in the middle of next year and then go into the crewed flight test [in 2018].”

The rather distinctive, olive colored aluminum domes are manufactured using a weldless spin forming process by Spincraft, based in North Billerica, Massachusetts.

They take on their honeycombed look after being machined for the purposes of reducing weight and increasing strength to handle the extreme stresses of spaceflight. The lower dome is machined by Janicki Industries in Layton, Utah, and the upper dome is machined by Major Tool & Machine in Indianapolis.

Overhead view of the docking hatch for the Boeing Starliner Spacecraft 1 assembly which technicians will soon join to the upper dome in the firm’s Commercial Crew and Cargo Processing Facility high bay at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com

Engineers bolted together the upper and lower domes of Boeings maiden Starliner crew module in early May to form the complete hull of the pressure vessel for the Structural Test Article (STA).

Altogether they are held together by 216 bolts. They have to line up perfectly. And the seals are checked to make sure there are no leaks, which could be deadly in space.

Boeing expects to finish fabricating the STA by August.

The completed Starliner STA will then be transported to Boeing’s facility in Huntington Beach, California for a period of critical stress testing that verifies the capabilities and worthiness of the spacecraft.

“Boeing’s testing facility in Huntington Beach, California has all the facilities to do the structural testing and apply loads. They are set up to test spacecraft,” said Danom Buck, manager of Boeing’s Manufacturing and Engineering team at KSC, during an interview in the C3PF.

“At Huntington Beach we will test for all of the load cases that the vehicle will fly in and land in – so all of the worst stressing cases.”

“So we have predicted loads and will compare that to what we actually see in testing and see whether that matches what we predicted.”

Boeing has also vastly updated the mockup Starliner to reflect the latest spacecraft advances and assist in manufacturing the three planned flight units.

Bastian Technologies built many of the components for the mockup and signed as new 18-month new Mentor-Protégé Program agreement with Boeing and NASA at the media event.

The mock up “is used as a hands-on way to test the design, accessibility and human factors during the early design and development phase of the program. The mock-up is currently being used for rapid fire engineering verification activities, ergonomic evaluations [including the seats and display panels], and crew ingress and egress training,” says NASA.

Looking inside the newly upgraded Starliner mockup with display panel, astronauts seats, gear and hatch at top that will dock to the new International Docking Adapter (IDA) on the ISS. Credit: Ken Kremer/kenkremer.com

The Boeing CST 100 Starliner is one of two private astronaut capsules – along with the SpaceX Crew Dragon – being developed under a commercial partnership contract with NASA to end our sole reliance on Russia for crew launches back and forth to the International Space Station (ISS).

The goal of NASA’s Commercial Crew Program (CCP) is to restore America’s capability to launch American astronauts on American rockets from American soil to the ISS, as soon as possible.

Since the retirement of NASA’s space shuttle program in 2011, the US was been 100% dependent on the Russian Soyuz capsule for astronauts rides to the ISS at a cost exceeding $70 million per seat.

Starliners will launch to space atop the United Launch Alliance (ULA) Atlas V rocket from pad 41 on Cape Canaveral Air Force Station in Florida.

A United Launch Alliance (ULA) Atlas V rocket carrying the NROL-61 surveillance satellite for the National Reconnaissance Office (NRO) lifts off from Space Launch Complex-41 on July 28, 2016 at 8:37 a.m. EDT from Cape Canaveral Air Force Station, FL. Credit: Ken Kremer/kenkremer.com — The Boeing Starliner will launch on a United Launch Alliance (ULA) Atlas V rocket similar to the one carrying the NROL-61 surveillance satellite for the National Reconnaissance Office (NRO) from Space Launch Complex-41 on July 28, 2016 at 8:37 a.m. EDT from Cape Canaveral Air Force Station, FL. Credit: Ken Kremer/kenkremer.com

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

Ken Kremer

Boeing ‘Starliner’ commercial crew space taxi manufacturing facility marks Grand Opening at the Kennedy Space Center on Sept 4. 2015. Exterior view depicting newly installed mural for the Boeing Company’s newly named CST-100 ‘Starliner’ commercial crew transportation spacecraft on the company’s Commercial Crew and Cargo Processing Facility (C3PF) at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer /kenkremer.com — Boeing ‘Starliner’ commercial crew space taxi manufacturing facility at the Kennedy Space Center. Exterior view depicts mural for the Boeing Company’s recently named CST-100 ‘Starliner’ commercial crew transportation spacecraft on the company’s Commercial Crew and Cargo Processing Facility (C3PF) at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer /kenkremer.com

August 4, 2016August 6, 2016 by Ken Kremer

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

Looking up to the 5 pairs of newly installed massive work platforms inside High Bay 3 of the Vehicle Assembly Building required to assemble NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com — 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 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. See our exclusive up close photos herein – detailing the huge ongoing effort.

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.”

A heavy-lift crane lifts the first half of the F-level work platforms, F south, for NASA’s Space Launch System rocket, into position for installation July 15, in High Bay 3 of the Vehicle Assembly Building at NASA’s Kennedy Space Center in Florida. Photo credit: NASA/Bill White

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 human 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, hoisting, fastening, banging and clanging and workers moving equipment and gear around.

Welding work in progress by workers in the VAB transfer aisle for installation of huge work platforms inside High Bay 3 at KSC on July 28, 2016. Credit: Julian Leek

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 platform halves, denoted as the North and South side platforms.

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. Heavy duty cranes are used to install the new platforms which will enable access to assemble NASA’s SLS rocket at KSC in Florida. Credit: Julian Leek

What’s the status today?

“We are looking up at 5 of 10 platform levels with 10 of 20 platform 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.”

Up close view looking out to the edge of Platform F showing the outer mold line snaking around the SLS core stage and a solid rocket booster from the 190 foot level under construction inside the VAB High Bay 3 on July 28, 2016 at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com

So much work was visible and actively in progress I definitely got the feeling from the ground up that NASA is now rapidly moving into the 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 in the VAB transfer aisle and are 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.”

Two halves of Platform D sit in the VAB transfer aisle on July 28, 2016 awaiting installation into High Bay 3. The new platforms give technicians access to assemble NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com

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 atop the 380 foot tall Mobile Launcher – 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.

Here’s the view looking out to Platform F:

View looking out to both halves of Platform F and down to Platform G showing the outer mold line snaking around the SLS core stage and a solid rocket booster from the 190 foot level under construction inside the VAB High Bay 3 on July 28, 2016 at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com

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!”

Looking up from beneath the enlarged exhaust hole of the Mobile Launcher to the 380 foot-tall tower astronauts will ascend as their gateway for missions to the Moon, Asteroids and Mars. The ML will support NASA's Space Launch System (SLS) and Orion spacecraft during Exploration Mission-1 at NASA's Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com — Looking up from beneath the enlarged exhaust hole of the Mobile Launcher to the 380 foot-tall tower astronauts will ascend as their gateway for missions to the Moon, Asteroids and Mars. The ML will support NASA’s Space Launch System (SLS) and Orion spacecraft during Exploration Mission-1 at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com

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.

Looking190 feet down from Platform F to the VAB floor along all five newly installed access platforms in High Bay 3. Construction worker on Platform G below is working near the outer mold line for the SLS rocket that will fill this space by early 2018 at KSC in Florida. Credit: Ken Kremer/kenkremer.com — Looking 190 feet down from Platform F to the VAB floor along all five newly installed access platforms in High Bay 3. Construction worker on Platform G below is working near the outer mold line for the SLS rocket that will fill this space by early 2018 at KSC in Florida. Credit: Ken Kremer/kenkremer.com

‘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!”

NASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC

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

Ken Kremer

Looking down from newly installed VAB High Bay 3 Platform F to Platform G on July 28, 2016. New platforms enable access to assemble NASA’s SLS rocket at KSC in Florida. Credit: Julian Leek

US Flag hangs proudly inside the VAB - America’s Premier Spaceport to Deep Space. Credit: Lane Hermann — US Flag hangs proudly inside the VAB – America’s Premier Spaceport to Deep Space. Credit: Lane Hermann

View of the VAB and Mobile Launcher from the KSC Launch Complex 39 Press Site. NASA is upgrading the VAB with new platforms to assemble and launch NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com

Floor level view of the Mobile Launcher and enlarged exhaust hole with 380 foot-tall launch tower astronauts will ascend as their gateway for missions to the Moon, Asteroids and Mars. The ML will support NASA's Space Launch System (SLS) and Orion spacecraft for launches from Space Launch Complex 39B the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com — Floor level view of the Mobile Launcher and enlarged exhaust hole with 380 foot-tall launch tower astronauts will ascend as their gateway for missions to the Moon, Asteroids and Mars. The ML will support NASA’s Space Launch System (SLS) and Orion spacecraft for launches from Space Launch Complex 39B the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com

July 24, 2016July 25, 2016 by Ken Kremer

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, on 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 — 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.”

And welding of the liquid hydrogen flight tank is moving along well.

“We will be complete with all SLS core stage flight tank welding in the VAC by the end of September,” added Jackie Nesselroad, SLS Boeing manager at Michoud. “It’s coming up very quickly!”

“The welding of the forward dome to barrel 1 on the liquid hydrogen flight tank is complete. And we are doing phased array ultrasonic testing right now!”

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.

The newly assembled 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 (blue) on July 22, 2016. It was lifted out of the welder (top) after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com — The newly assembled 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 (blue) on July 22, 2016. It was lifted out of the welder (top) after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com

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.

Up close view of the dome of the newly assembled first ever liquid hydrogen test tank for NASA's new Space Launch System (SLS) heavy lift rocket on July 22, 2016 after it was welded together at NASA’s Michoud Assembly Facility in New Orleans. Sensors will be attached to both ends for upcoming structural loads and proof testing. Credit: Ken Kremer/kenkremer.com — Up close view of the dome of the newly assembled first ever liquid hydrogen test tank for NASA’s new Space Launch System (SLS) heavy lift rocket on July 22, 2016 after it was welded together at NASA’s Michoud Assembly Facility in New Orleans. Sensors will be attached to both ends for upcoming structural loads and proof testing. Credit: Ken Kremer/kenkremer.com

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, Nesselroad explained.

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 LH2 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 Vertical Weld Center tool used to fabricate barrel segments for the SLS liquid hydrogen and oxygen core stage tanks via vertical friction stir welding operations at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com

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 Gore Weld Tool (foreground) and Circumferential Dome Weld Tool (background) Center tool used to fabricate dome segments for the SLS liquid hydrogen and oxygen core stage tanks via vertical friction stir welding operations at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com — The Gore Weld Tool (foreground) and Circumferential Dome Weld Tool (background) used to fabricate dome segments for the SLS liquid hydrogen and oxygen core stage tanks via vertical friction stir welding operations at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com

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

………….

Learn more about SLS and Orion crew vehicle, SpaceX CRS-9 rocket launch, ISS, ULA Atlas and Delta rockets, Juno at Jupiter, Orbital ATK Antares & Cygnus, Boeing, Space Taxis, Mars rovers, NASA missions and more at Ken’s upcoming outreach events:

July 27-28: “ULA Atlas V NRO Spysat launch July 28, SpaceX launch to ISS on CRS-9, SLS, Orion, Juno at Jupiter, ULA Delta 4 Heavy NRO spy satellite, Commercial crew, Curiosity explores Mars, Pluto and more,” Kennedy Space Center Quality Inn, Titusville, FL, evenings

Graphic shows all the dome, barrel, ring and engine components used to assemble the five major structures of the core stage of NASA’s Space Launch System (SLS) in Block 1 configuration. Credits: NASA/MSFC

At NASA’s Michoud Assembly Facility in New Orleans, Patrick Whipps/NASA SLS Stages Element Manager and Ken Kremer/Universe Today discuss details of SLS manufacture by the Circumferential Dome Weld Tool used to fabricate dome segments for the SLS liquid hydrogen and oxygen core stage tanks. Credit: Ken Kremer/kenkremer.com

Graphic shows Block I configuration of NASA’s Space Launch System (SLS). Credits: NASA/MSFC

July 20, 2016July 21, 2016 by Ken Kremer

Flawless Capture and Berthing of SpaceX Dragon Supply Ship at ISS

KENNEDY SPACE CENTER, FL – Following a flawless post midnight blastoff two mornings ago, a pair of NASA astronauts executed a flawless capture of the newest SpaceX Dragon supply ship at the International Space Station early this morning, July 20, carrying 2.5 tons of priceless research equipment and gear for the resident astronauts and cosmonauts.

As the orbiting outpost was traveling 252 statute miles over the Great Lakes, NASA’s veteran Expedition 48 Commander Jeff Williams and newly arrived NASA Flight Engineer Kate Rubins used the station’s 57.7-foot (17.6-meter) Canadian-built robotic arm to reach out and capture the Dragon CRS-9 spacecraft at 6:56 a.m. EDT.

“Good capture confirmed after a two day rendezvous,” said Houston Mission Control at NASA’s Johnson Space Center, as Dragon was approximately 30 feet (10 meters) away from the station.

“We’ve captured us a Dragon,” radioed Williams.

“Congratulations to the entire team that put this thing together, launched it, and successfully rendezvoused it to the International Space Station. We look forward to the work that it brings.”

The SpaceX Dragon is seen attached to the International Space Station’s Harmony module just before orbital sunrise. Credit: NASA TV

The events unfolded live on a NASA TV webcast for all to follow along.

Furthermore, today’s dramatic Dragon arrival coincides with a renowned day in the annuls of space history. Today coincides with the 40th anniversary of humanity’s first successful touchdown on the surface of Mars by NASA’s Viking 1 lander on July 20, 1976. It paved the way for many future missions.

And Neil Armstrong and Buzz Aldrin were the first humans to land on another celestial body – the Moon – on July 20, 1969 during NASA’s Apollo 11 lunar landing mission.

Williams was working from a robotics work station in the station’s domed cupola. Rubins was Williams backup. She just arrived at the station on July 9 for a minimum 4 month stay, after launching to orbit on a Russian Soyuz on July 6 with two additional crew mates.

Ground controllers then used the robotic arm to maneuver the Dragon cargo spacecraft closer to its berthing port on the Earth facing side of the Harmony module, located at the front of the station.

Some three hours after the successful grappling, Dragon was joined to the station and bolted into place for initial berthing on the Harmony module at 10:03 a.m. EDT as the station flew about 252 statute miles over the California and Oregon border.

Controllers then activated four gangs of four bolts in the common berthing mechanism (CBM) to complete the second stage capture of the latching and berthing of Dragon to the station with a total of 16 bolts to ensure a snug connection, safety and no pressure leaks.

Crew members Williams and Rubins along with Japanese astronaut Takuya Onishi are now working to install power and data cables from the station to Dragon. They plan to open the hatch tomorrow after pressurizing the vestibule in the forward bulkhead between the station and Dragon.

Dragon reached the station after a carefully choreographed orbital chase and series of multiple thruster firings to propel the cargo ship from its preliminary post launch orbit up to the massive million pound science outpost with six resident crew members from the US, Russia and Japan.

Among the 5000 pounds of equipment on board is the first of two identical docking adapters essential for enabling station dockings next year by NASA’s new commercial astronaut taxis. This mission is all about supporting NASA’s ‘Journey to Mars’ by humans in the 2030s.

Liftoff of the SpaceX Falcon 9 rocket in its upgraded, full thrust version and the Dragon CRS-9 resupply ship took place barely 48 hours ago at 12:45 a.m. EDT Monday, July 18, from Space Launch Complex 40 at Cape Canaveral Air Force Station in Florida.

Dragon reached its preliminary orbit about 10 minutes after launch and then deployed a pair of solar arrays.

SpaceX also successfully executed a spellbinding ground landing of the Falcon 9 first stage back at Cape Canaveral Air Force Station’s Landing Zone 1, located a few miles south of launch pad 40.

The dramatic ground landing of the 156 foot tall Falcon 9 first stage at LZ -1 took place about 9 minutes after liftoff. It marks only the second time a spent orbit class booster has touched down intact and upright on land.

Among the wealth of over 3900 pounds (1790 kg) of research investigations loaded on board Dragon is an off the shelf instrument designed to perform the first-ever DNA sequencing in space and the first international docking adapter (IDA) that is absolutely essential for docking of the SpaceX and Boeing built human spaceflight taxis that will ferry our astronauts to the International Space Station (ISS) in some 18 months.

Other science experiments on board include OsteoOmics to test if magnetic levitation can accurately simulate microgravity to study different types of bone cells and contribute to treatments for diseases like osteoporosis, a Phase Change Heat Exchanger to test temperature control technology in space, the Heart Cells experiments that will culture heart cells on the station to study how microgravity changes the human heart, new and more efficient three-dimensional solar cells, and new marine vessel tracking hardware known as the Automatic Identification System (AIS) that will aid in locating and identifying commercial ships across the globe.

The ring shaped IDA-2 unit is stowed in the Dragon’s unpressurized truck section. It weighs 1029 lbs (467 kg), measures about 42 inches tall and sports an inside diameter of 63 inches in diameter – so astronauts and cargo can easily float through. The outer diameter measures about 94 inches.

“Spacecraft flying to the station will use the sensors on the IDA to track to and help the spacecraft’s navigation system steer the spacecraft to a safe docking without astronaut involvement.”

CRS-9 counts as the company’s ninth scheduled flight to deliver supplies, science experiments and technology demonstrations to the International Space Station (ISS).

The CRS-9 mission is for the crews of Expeditions 48 and 49 to support dozens of the approximately 250 science and research investigations in progress under NASA’s Commercial Resupply Services (CRS) contract.

Up close view of SpaceX Dragon CRS-9 resupply ship and solar panels atop Falcon 9 rocket at pad 40 prior to blastoff to ISS on July 18, 2016 from Cape Canaveral Air Force Station, Florida. Credit: Ken Kremer/kenkremer.com

Dragon will remain at the station until its scheduled departure on Aug. 29 when it will return critical science research back to Earth via a parachute assisted splashdown in the Pacific Ocean off the California coast.

Watch for Ken’s continuing CRS-9 mission coverage where he reported onsite direct from the Kennedy Space Center and Cape Canaveral Air Force Station, Florida.

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

Ken Kremer

July 18, 2016July 23, 2016 by Ken Kremer

SpaceX Nails Mesmerizing Midnight Launch and Land Landing of Falcon 9 Carrying Critical ISS Science and Docking Port

A team of engineers from the University of Glasgow and the Ukraine have created an engine that could cut costs by "eating itself". Credit: Ken Kremer/kenkremer.com

KENNEDY SPACE CENTER, FL – In a breathtaking feat mesmerizing hordes of thrilled spectators, SpaceX nailed today’s (July 18) back to back post midnight launch and landing of the firms Falcon 9 first stage tasked to carry a cargo Dragon loaded with over two tons of critical science, supplies and a crew docking port to the space station for NASA.

Liftoff of the SpaceX Falcon 9 rocket in its upgraded, full thrust version and the Dragon CRS-9 resupply ship took place right on time at 12:45 a.m. EDT Monday, July 18, from Space Launch Complex 40 at Cape Canaveral Air Force Station in Florida.

SpaceX simultaneously successfully delivered over 5000 pounds (2200 kg) of research supplies to orbit for NASA in a commercial cargo Dragon ship, as the primary mission goal – and soft landed the approximately 60,000 pound Falcon 9 first stage on land, as the experimental secondary mission goal.

“The Falcon 9 first stage we landed is in excellent shape,” Hans Koenigsmann, SpaceX vice president of Flight Reliability, told Universe Today at the 2 a.m. EDT post launch and landing media briefing early this morning.

See my launch and landing streak shot and photos herein, including deployment of the four landing legs in the final seconds before propulsive touchdown.

The twin accomplishments will have far reaching implications for the exploration and exploitation of space for all humanity.

“Each commercial resupply flight to the space station is a significant event. Everything, from the science to the spare hardware and crew supplies, is vital for sustaining our mission,” said Kirk Shireman, NASA’s International Space Station Program manager.

“With equipment to enable novel experiments never attempted before in space, and an international docking adapter vital to the future of U.S. commercial crew spacecraft, we’re thrilled this Dragon has successfully taken flight.”

The CRS-9 mission is to support the resident six-person crew of men and women currently working on the station from the US, Russia and Japan.

The propulsive soft landing of the 156 foot tall Falcon 9 first stage of the Falcon 9 rocket on land at Cape Canaveral Air Force Station’s Landing Zone 1, located a few miles south of launch pad 40.

The dramatic ground landing at LZ -1 took place about 9 minutes after liftoff.

The first and second stages separated about two and a half minutes after liftoff and were easily visible to any eyewitness watching – backdropped by the sunshine states dark skies.

As the second stage soared to orbit, the first stage reignited a first stage engine for a series of burns targeting a return to the Cape.

We spotted the first engine firing about two mintues before landing, as it descended directly overhead of myself and everyone in the Cape Canaveral region.

For a few moments it looked like it was headed right towards us, but then steered away as planned with engines blazing to slow the boosters descent to make a gentle landing at LZ-1.

Finally the Falcon landed, obscured by a big vapor cloud and sonic booms roaring around the space coast – and waking many local residents. Several folks told me they were suddenly woken by the shocking booms reverberating inside their homes.

Some area residents even called 911 not knowing the true nature of the noises.

Streak shot of launch and landing of SpaceX Falcon CRS-9 mission from Cape Canaveral Air Force Station, Florida to the ISS on July 18, 2016 at 12:45 a.m. EDT. View from Satellite Beach, FL. Credit: John Krauss/johnkraussphotos.com

Among the wealth of over 3900 pounds (1790 kg) of research investigations loaded on board Dragon is an off the shelf instrument designed to perform the first-ever DNA sequencing in space, and the first international docking adapter (IDA) that is absolutely essential for docking of the SpaceX and Boeing built human spaceflight taxis that will ferry our astronauts to the International Space Station (ISS) in some 18 months.

Blastoff of SpaceX Falcon 9 on Dragon CRS-9 resupply mission to the International Space Station (ISS) at 12:45 a.m. EDT on July 18, 2016. Credit: Ken Kremer/kenkremer.com

CRS-9 counts as the company’s ninth scheduled flight to deliver supplies, science experiments and technology demonstrations to the International Space Station (ISS).

Dragon reached its preliminary orbit about 10 minutes after launch. Then it deployed a pair of solar arrays and began a carefully choreographed series of thruster firings to reach the space station.

If all goes well, Dragon is scheduled to arrive at the orbiting outpost on Wednesday, July 20, after a 2 day orbital chase.

NASA astronaut Jeff Williams will then reach out with the station’s 57.7-foot-long Canadian-built robotic arm to grapple and capture the private Dragon cargo ship working from a robotics work station in the station’s cupola. NASA astronaut Kate Rubins will serve as Williams backup. She just arrived at the station last week on July 9 for a minimum 4 month stay, after launching to orbit on a Russian Soyuz on July 6 with two additional crew mates.

Ground commands will be sent from Houston to the station’s arm to install Dragon on the Earth-facing bottom side of the Harmony module for its stay at the space station. The crew expects to open the hatch a day later after pressurizing the vestibule in the forward bulkhead between the station and Dragon.

Live coverage of the rendezvous and capture July 20 will begin at 5:30 a.m. on NASA TV, with installation coverage set to begin at 9:45 a.m.

CRS-9 marks only the second time SpaceX has attempted a land landing of the 15 story tall first stage booster.

The history making first time successfully took place at Landing Zone 1 (LZ 1) on Dec. 22, 2015 as part of the ORBCOMM-2 mission. Landing Zone 1 is built on the former site of Space Launch Complex 13, a U.S. Air Force rocket and missile testing range.

SpaceX also successfully recovered first stages three times in a row at sea this year on an ocean going drone ship barge using the company’s OCISLY Autonomous Spaceport Drone Ship (ASDS) on April 8, May 6 and May 27.

Altogether SpaceX has successfully landed and recovered 5 first stage booster intact and upright.

The International Docking Adapter-2 was tested in the Space Station Processing Facility prior to being loaded for launch into space on the SpaceX CRS-9 mission set for July 18, 2016 from Cape Canaveral, Fl. Credits: NASA — The International Docking Adapter-2 was tested in the Space Station Processing Facility prior to being loaded for launch into space on the SpaceX CRS-9 mission [set for July 18, 2016 from Cape Canaveral, Fl. Credits: NASA

Watch for Ken’s onsite CRS-9 mission reports direct from the Kennedy Space Center and Cape Canaveral Air Force Station, Florida.

Here’s my launch pad video of the blastoff:

Video caption: SpaceX Falcon 9 lifts off with Dragon CRS-9 resupply ship bound for the International Space Station on July 18, 2016 at 12:45 a.m. EDT from Space Launch Complex 40 at Cape Canaveral Air Force Station, Fl, as seen in this up close video from Mobius remote camera positioned at the pad. Credit: Ken Kremer/kenkremer.com

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

Ken Kremer

………….

Learn more about Juno at Jupiter, SpaceX CRS-9 rocket launch, ISS, ULA Atlas and Delta rockets, Orbital ATK Cygnus, Boeing, Space Taxis, Mars rovers, Orion, SLS, Antares, NASA missions and more at Ken’s upcoming outreach events:

July 18, 26-28: “SpaceX launches to ISS on CRS-9, Juno at Jupiter, ULA Delta 4 Heavy and Atlas V spy satellite launches, SLS, Orion, Commercial crew, Curiosity explores Mars, Pluto and more,” Kennedy Space Center Quality Inn, Titusville, FL, evenings

July 16, 2016July 17, 2016 by Ken Kremer

SpaceX Midnight Launch Carrying Crucial Docking Port and Science to ISS Set for July 18, Plus Loud Land Landing – Watch Live

SpaceX conducts Falcon 9 Dragon CRS-9 mission static fire test ahead of planned 18 July 2016 liftoff from Cape Canaveral Air Force Station in Florida at 12:45 a.m. EDT. View from atop Launch Complex 39B at the Kennedy Space Center. Credit: Ken Kremer/kenkremer.com

KENNEDY SPACE CENTER, FL – The outlook is outstanding for a dramatic midnight blastoff of the next SpaceX commercial cargo Dragon jam packed with some 5000 pounds of critical payloads and research supplies for NASA and heading to the space station on Monday, July 18 – that also simultaneously features an experimental land landing that promises to rock loudly across the Florida space coast and one day slash launch costs.

Dragon is carrying a crucial crew docking port absolutely essential for conducting future human space missions to the orbiting outpost as well as a host of wide ranging science experiments essential for NASA exploiting the space environment for research in low earth orbit and deep space exploration.

Liftoff of the SpaceX Falcon 9 rocket in its upgraded, full thrust version and the Dragon CRS-9 resupply ship is targeted for 12:45 a.m. EDT Monday, July 18, from Space Launch Complex 40 at Cape Canaveral Air Force Station in Florida.

The CRS-9 mission is to support the resident six-person crew of men and women currently working on the station from the US, Russia and Japan.

Spectators are filling local area hotels in anticipation of a spectacular double whammy sky show comprising a thunderous nighttime launch streaking to orbit – followed minutes later by a brilliant rocket flash and night landing back at the Cape of the Falcon first stage that will send sonic booms roaring all around the coast and surrounding inland areas.

SpaceX has confirmed they are attempting the secondary mission of landing the 156 foot tall first stage of the Falcon 9 rocket on land at Cape Canaveral Air Force Station’s Landing Zone 1, located a few miles south of launch pad 40.

The weather and technical outlook for the 229 foot-tall (70 meter) Falcon 9 looks fantastic at this time, a day before liftoff.

The official weather forecast from Air Force meteorologists with the 45th Space Wing calls for a 90 percent chance of “GO” with extremely favorable conditions at launch time for liftoff of this upgraded, SpaceX Falcon 9.

The only concerns are for Cumulus clouds building up and a chance of precipitation.

And for added stargazers delight the night sky features a full moon.

The SpaceX/Dragon CRS-9 launch coverage will be broadcast on NASA TV beginning at 11:30 p.m. EDT Sunday, July 17, with additional commentary on the NASA launch blog.

SpaceX will also feature their own live webcast beginning approximately 20 minutes before launch at 12:25 a.m. EDT Monday, July 18

You can watch the launch live at NASA TV at – http://www.nasa.gov/nasatv

You can watch the launch live at SpaceX Webcast at – spacex.com/webcast

The launch window is instantaneous, meaning that any delays due to weather or technical issues will results in a minimum 2 day postponement.

If the launch does not occur Monday, a backup launch opportunity exists on 12 a.m. Wednesday, July 20, just seconds after midnight, with NASA TV coverage starting at 10:45 p.m. EDT Tuesday, July 19.

CRS-9 marks only the second time SpaceX has attempted a land landing of the 15 story tall first stage booster.

The history making first time took place at Landing Zone 1 (LZ 1) on Dec. 22, 2015 as part of the ORBCOMM-2 mission. Landing Zone 1 is built on the former site of Space Launch Complex 13, a U.S. Air Force rocket and missile testing range.

SpaceX issued a statement describing how local area residents could hear sonic booms – similar to those heard during landings of NASA’s space shuttles.

“There is the possibility that residents of northern and central Brevard County, Fla. may hear one or more sonic booms during landing. A sonic boom is a brief thunder-like noise a person on the ground hears when an aircraft or other vehicle flies overhead faster than the speed of sound,” said SpaceX.

Who could be affected?

“Residents of the communities of Cape Canaveral, Cocoa, Cocoa Beach, Courtenay, Merritt Island, Mims, Port Canaveral, Port St. John, Rockledge, Scottsmoor, Sharpes, and Titusville in Brevard County, Fla. are most likely to hear a sonic boom, although what residents experience will depend on weather conditions and other factors.”

The sights and sound are certain to be thrilling- so catch it if you can!

CRS-9 counts as the company’s ninth scheduled flight to deliver supplies, science experiments and technology demonstrations to the International Space Station (ISS).

SpaceX engineers conducted their standard static fire hold down test of the first stages Merlin 1D engines with the rocket erect at pad 40, this morning Saturday, July 16.

The customary test lasts a few seconds and was conducted with the Dragon bolted on top at about 9:30 a.m. I saw the test while visiting atop neighboring Launch Complex 39B at the Kennedy Space Center – see photo.

“All looks good,” reported Hans Koenigsmann, SpaceX vice president of Flight Reliability, at a media briefing this afternoon.

“We expect a GO for launch.”

Dragon will reach its preliminary orbit about 10 minutes after launch. Then it will deploy its solar arrays and begin a carefully choreographed series of thruster firings to reach the space station.

If all goes well, Dragon will arrive at the orbiting outpost on Wednesday, July 20, after a 2 day orbital chase.

Live coverage of the rendezvous and capture July 20 will begin at 5:30 a.m. on NASA TV, with installation coverage set to begin at 9:45 a.m.

Perhaps the most critical payload relating to the future of humans in space is the 1,020-pound international docking adapter known as IDA-2 or International Docking Adapter-2.

Here’s an early morning video view of Falcon 9 on the pad today.

Video Caption: Early morning shots of CRS-9 ready for flight on Monday July 18 at 12:45 AM. Credit: USLaunchReport

Watch for Ken’s onsite CRS-9 mission reports direct from the Kennedy Space Center and Cape Canaveral Air Force Station, Florida.

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

Ken Kremer

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July 15-18: “SpaceX launches to ISS on CRS-9, Juno at Jupiter, ULA Delta 4 Heavy spy satellite, SLS, Orion, Commercial crew, Curiosity explores Mars, Pluto and more,” Kennedy Space Center Quality Inn, Titusville, FL, evenings

Former astronaut Bob Cabana, director of NASA's Kennedy Space Center in Florida, surveys the IDA-2 inside the Space Station Processing Facility. Credits: NASA — Former astronaut Bob Cabana, director of NASA’s Kennedy Space Center in Florida, surveys the IDA-2 inside the Space Station Processing Facility. Credits: NASA

SpaceX Dragon CRS-9 mission logo. Credit: SpaceX