Will 2016 Be the Year Elon Musk Reveals his Mars Colonial Transporter Plans?

Musk wants to see his "Red Dragon" on the surface of Mars within the next 20 years. Image Credit: SpaceX

There are several space stories we’re anticipating for 2016 but one story might appear — to some — to belong in the realm of science fiction: sometime in the coming year Elon Musk will likely reveal his plans for colonizing Mars.

Early in 2015, Musk hinted that he would be publicly disclosing his strategies for the Mars Colonial Transport system sometime in late 2015, but then later said the announcement would come in 2016.

“The Mars transport system will be a completely new architecture,” Musk said during a Reddit AMA in January 2015, replying to a question about the development of MCT. “[I] am hoping to present that towards the end of this year. Good thing we didn’t do it sooner, as we have learned a huge amount from Falcon and Dragon.”

Big Rockets

As far as any details, Musk only said that he wants to be able to send 100 colonists to Mars at a time, and the “goal is 100 metric tons of useful payload to the surface of Mars. This obviously requires a very big spaceship and booster system.”

He has supposedly dubbed the rocket the BFR (for Big F’n Rocket) and the spaceship similarly as BFS.

And he wants it to be reusable, which Musk and SpaceX have said is the key to making human life multiplanetary. The recent successful return and vertical landing of the Falcon 9’s first stage makes that closer to reality than ever.

While SpaceX has no publicly shared concept illustrations as of yet, a few enthusiasts on the web have shared their visions of MCT, such as this discussion on Reddit , and the drawing below by engineer John Gardi, who recently proposed his ideas for the MCT on Reddit.

A sketch shows how the top section of the Mars Colonial Transporter might be configured. Credit: John Gardi.
A sketch shows how the top section of the Mars Colonial Transporter might be configured. Credit: John Gardi.

Most online discussions describe the MCT as an interplanetary ferry, with the spaceship built on the ground and launched into orbit in one piece and perhaps refueled in low Earth orbit. The transporter could be powered by Raptor engines, which are cryogenic methane-fueled rocket engines rumored to be under development by SpaceX.

The future line-up of Falcon rockets is compared to the famous NASA Saturn V. The first Falcon Heavy launch is planned for 2015. Raptor engines may replace and upgrade Heavy then lead to Falcon X, Falcon X Heavy and Falcon XX. The Falcon X 1st stage would have half the thrust of a Saturn V, Falcon X Heavy and XX would exceed a Saturn V's thrust by nearly 50%. (Illustration Credit: SpaceX, 2010)
The future line-up of Falcon rockets is compared to the famous NASA Saturn V. The first Falcon Heavy launch is planned for 2015. Raptor engines may replace and upgrade Heavy then lead to Falcon X, Falcon X Heavy and Falcon XX. The Falcon X 1st stage would have half the thrust of a Saturn V, Falcon X Heavy and XX would exceed a Saturn V’s thrust by nearly 50%. (Illustration Credit: SpaceX, 2010)

The Challenge of Landing Large Payloads on Mars

While the big rocket and spaceship may seem to be a big hurdle, an even larger challenge is how to land a payload of 100 metric tons with 100 colonists, as Musk proposes, on Mars surface.

As we’ve discussed previously, there is a “Supersonic Transition Problem” at Mars. Mars’ thin atmosphere does not provide an enough aerodynamics to land a large vehicle like we can on Earth, but it is thick enough that thrusters such as what was used by the Apollo landers can’t be used without encountering aerodynamic problems such as sheering and incredible stress on the vehicle.

Another fan-based illustration of the modular sections of John Gardi's MCT concept sitting on the surface of Mars. Credit: George Worthington. Used by permission.
Another fan-based illustration of the modular sections of John Gardi’s MCT concept sitting on the surface of Mars. Credit: George Worthington. Used by permission.

“Unique to Mars, there is a velocity-altitude gap below Mach 5,” explained Rob Manning from the Jet Propulsion Laboratory in our article from 2007. “The gap is between the delivery capability of large entry systems at Mars and the capability of super-and sub-sonic decelerator technologies to get below the speed of sound.”

With current landing technology, a large, heavy human-sized vehicle streaking through Mars’ thin, volatile atmosphere only has about 90 seconds to slow from Mach 5 to under Mach 1, change and re-orient itself from a being a spacecraft to a lander, deploy parachutes to slow down further, then use thrusters to translate to the landing site and gently touch down.

90 seconds is not enough time, and the airbags used for rovers like Spirit and Opportunity and even the Skycrane system used for the Curiosity rover can’t be scaled up enough to land the size of payloads needed for humans on Mars.

Artist’s rendering of a hypersonic inflatable aerodynamic decelerator technology concept. Credit: NASA.
Artist’s rendering of a hypersonic inflatable aerodynamic decelerator technology concept. Credit: NASA.

NASA has been addressing this problem to a small degree, and has tested out inflatable aeroshells that can provide enough aerodynamic drag to decelerate and deliver larger payloads. Called Hypersonic Inflatable Aerodynamic Decelerator (HIAD), this is the best hope on the horizon for landing large payloads on Mars.

The Inflatable Reentry Vehicle Experiment (IRVE-3) was tested successfully in 2012. It was made of high tech fabric and inflated to create the shape and structure similar to a mushroom. When inflated, the IRVE-3 is about 10-ft (3 meter) in diameter, and is composed of a seven giant braided Kevlar rings stacked and lashed together – then covered by a thermal blanket made up of layers of heat resistant materials. These kinds of aeroshells can also generate lift, which would allow for additional slowing of the vehicle.

“NASA is currently developing and flight testing HIADs — a new class of relatively lightweight deployable aeroshells that could safely deliver more than 22 tons to the surface of Mars,” said Steve Gaddis, GCD manager at NASA’s Langley Research Center in a press release from NASA in September 2015.

NASA is expecting that a crewed spacecraft landing on Mars would weigh between 15 and 30 tons, and the space agency is looking for ideas through its Big Idea Challenge for how to create aeroshells big enough to do the job.

With current technology, landing the 100 metric tons that Musk envisions might be out of reach. But if there’s someone who could figure it out and get it done, Elon Musk just might be that person.

Additional reading: Alan Boyle on Geekwire, GQ interview of Elon Musk.

SpaceX Targeting Dec. 19 ‘Return to Flight’ Liftoff for Falcon 9 after June Mishap

SpaceX Falcon 9 rocket with SES-8 communications satellite awaits launch from Pad 40 at Cape Canaveral, FL, file photo. Credit: Ken Kremer/kenkremer.com

SpaceX Falcon 9 rocket after successful static hot-fire test on June 13, 2014 on Pad 40 at Cape Canaveral, FL.  Launch is slated for Friday, June 20, 2014  on ORBCOMM OG2 mission with six OG2 satellites. Credit: Ken Kremer/kenkremer.com
SpaceX Falcon 9 rocket after successful static hot-fire test on June 13, 2014 on Pad 40 at Cape Canaveral, FL. Launch is slated for Friday, June 20, 2014 on ORBCOMM OG2 mission with six OG2 satellites. Credit: Ken Kremer/kenkremer.com
SpaceX announced today (Dec. 10) that the aerospace firm is now targeting Dec. 19 as the target date for the ‘Return to Flight’ of their Falcon 9 rocket, and comes approximately six months after their last launch in late June 2015 ended suddenly in a catastrophic mid-air calamity resulting in total destruction of the rocket carrying out a critical cargo mission for NASA to the International Space Station (ISS).

The Falcon 9 ‘Return to Flight’ launch attempt from Cape Canaveral, Florida was confirmed by SpaceX CEO and chief designer Elon Musk via twitter this morning.

The tentative Falcon 9 launch Continue reading “SpaceX Targeting Dec. 19 ‘Return to Flight’ Liftoff for Falcon 9 after June Mishap”

Cygnus Docks at Station for Christmas Delivery to Successfully Resume American Resupply Chain

@OrbitalATK’s #Cygnus spacecraft is moving toward its capture point at the International Space Station as astronaut maneuver the Canadian-built robotic arm to reach out for dramatic vehicle grappling on Dec. 9, 2015. Credit: NASA TV
@OrbitalATK’s #Cygnus spacecraft is moving toward its capture point at the International Space Station as astronaut maneuver the Canadian-built robotic arm to  reach out for dramatic vehicle grappling on Dec. 9, 2015. Credit: NASA TV
@OrbitalATK’s #Cygnus spacecraft is moving toward its capture point at the International Space Station as astronauts maneuver the Canadian-built robotic arm to reach out for dramatic vehicle grappling on Dec. 9, 2015. Credit: NASA TV
Story/photos updated

The commercial Cygnus cargo spaceship, loaded with over three tons of critically needed supplies and research experiments, successfully rendezvoused and docked with the International Space Station (ISS) this morning (Dec. 9) after blazing to orbit on Sunday, Dec. 6, and thereby successfully resumed the American resupply chain to orbit – just in time for Christmas in Space!

The Orbital ATK Cygnus CRS-4 resupply vessel arrived in the vicinity of the massive orbiting outpost around 530 a.m. EST today with pinpoint accuracy after precisely firing its maneuvering thrusters to home in on the complex during a two day orbital chase.

After moving close in to Continue reading “Cygnus Docks at Station for Christmas Delivery to Successfully Resume American Resupply Chain”

Spectacular Blastoff of Atlas Cygnus Ignites Restart of American Cargo Missions to ISS

Orbital ATK’s Cygnus Spacecraft carrying vital cargo to resupply the International Space Station lifts-off aboard a United Launch Alliance Atlas V rocket on Dec. 6, 2015. Credit: Ken Kremer/kenkremer.com
Orbital ATK’s Cygnus Spacecraft carrying vital cargo to resupply the International Space Station lifts-off aboard a United Launch Alliance Atlas V rocket.  Credit: Ken Kremer/kenkremer.com
Orbital ATK’s Cygnus Spacecraft carrying vital cargo to resupply the International Space Station lifts-off aboard a United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com
Story/photos updated

KENNEDY SPACE CENTER, FL – Today’s spectacular blastoff of a United Launch Alliance Atlas V rocket carrying an Orbital ATK Cygnus commercial resupply spacecraft ignited the restart of critically needed American cargo mission to the International Space Station (ISS) following a pair of launch failures over the past year.

The ULA Atlas V rocket roared off the launch pad at 4:44 p.m. EST at the opening of a 30 minute launch window from Space Launch Complex 41 at Cape Canaveral Air Force Station in Florida. Continue reading “Spectacular Blastoff of Atlas Cygnus Ignites Restart of American Cargo Missions to ISS”

Happy Marriage of ULA and Orbital ATK Set for Atlas V Blastoff of Cygnus Freighter to ISS on Dec. 6 – Watch NASA TV Live; Photos

Reflection view of Orbital ATK Cygnus CRS-4 spacecraft poised for blastoff to ISS on ULA Atlas V on Dec. 5, 2015 from Cape Canaveral Air Force Station, Florida. Credit: Ken Kremer/kenkremer.com
Reflection view of Orbital ATK Cygnus CRS-4 spacecraft poised for blastoff  to ISS on  ULA Atlas V on Dec. 5, 2015 from Cape Canaveral Air Force Station, Florida.  Credit: Ken Kremer/kenkremer.com
Reflection view of Orbital ATK Cygnus CRS-4 spacecraft poised for blastoff to ISS on ULA Atlas V on Dec. 5, 2015 from Cape Canaveral Air Force Station, Florida. Credit: Ken Kremer/kenkremer.com

KENNEDY SPACE CENTER, FL – The unplanned ‘Happy Marriage’ of United Launch Alliance (ULA) and Orbital ATK is set to give birth Sunday, Dec. 6, to a Cygnus cargo freighter bound for the International Space Station (ISS).

Following two scrubs and a three day due to intense and wide spread rain squalls and excessive blustery winds, the third time is hopefully the charm for the Orbital ATK Cygnus resupply ship set for blastoff atop the venerable ULA Atlas V booster.

The late afternoon liftoff is targeted for Continue reading “Happy Marriage of ULA and Orbital ATK Set for Atlas V Blastoff of Cygnus Freighter to ISS on Dec. 6 – Watch NASA TV Live; Photos”

Hayabusa 2 to Flyby the Earth Tomorrow

An artist's image of Hayabusa leaving Earth. Hayabusa was a Japanese sample return mission to the asteroid 25143 Itokawa. The mission was a partial success. A sample mission to Earth's sister planet is the holy-grail for the exploration of Venus. Image credit: JAXA

A space-faring friend pays our fair planet a visit this week on the morning of December 3rd, as the Japanese Space Agency’s Hayabusa 2 spacecraft passes the Earth.

The Flyby

Rick Baldridge on the SeeSat-L message board notes that Hayabusa-2 will pass 9,520 kilometers from the Earth’s center or 3,142 kilometers/1,885 miles from the Earth’s surface at 10:08 UT/5:08 AM EST on Thursday, December 3rd, passing from north-to-south above latitude 18.7 north, longitude 189.8 east just southwest of the Hawaiian Islands.

Unfortunately, the sighting opportunities for Hayabusa-2 aren’t stellar: even at its closest, the 1.5 meter-sized spacecraft is about nine times more distant than the International Space Station and satellites in low Earth orbit. To compound the challenge, Hayabusa-2 passes into the Earth’s shadow from 9:58 UT to 10:19 UT.

Image credit: JAXA
The path of Hayabusa-2 past the Earth. Image credit: JAXA

Still, skilled observers with large telescopes and sophisticated tracking rigs based along the Pacific Rim of North America might just catch sight of Hayabusa-2 as it speeds by. The JPL Horizons ephemeris generator is a great resource to create a customized positional chart in right ascension and declination for spacecraft for your given location, including Hayabusa-2.

Image credit: JAXA
The Earth-Moon pair snapped by Hayabusa-2 on November 26th from about three million kilometers distant. Image credit: JAXA

Hayabusa-2 won’t crack 20 degrees elevation for observers along the U.S. West Coast, putting it down in the atmospheric murk of additional air mass low to the horizon. This also tends to knock the brightness of objects down a magnitude or so… estimates place Hayabusa-2 at around magnitude +13 shortly before entering the Earth’s shadow. That’s pretty faint, but still, there are some dedicated observers with amazing rigs out there, and it’s quite possible someone could nab it. Hawaii-based observers should have the best shot at it, though again, it’ll be in the Earth’s shadow at its very closest…

Amateur radio satellite trackers are also on the hunt for the carrier-wave signal of the inbound Hayabusa-2 mission. You can also virtually fly along with the spacecraft until December 5th: (H/T @ImAstroNix):

A simulation of tomorrow's flyby. Image Credit: JAXA
A simulation of tomorrow’s flyby. Image Credit: JAXA

Probably the best eye-candy images will come from the spacecraft itself: already, Hayabusa-2 has already snapped some great images of the Earth-Moon pair using its ONC-T optical navigation camera during its inbound leg.

Image credit: JAXA
A close-up of Hayabusa-2’s view of the Earth and Moon. Image credit: JAXA

Other notable missions used Earth flybys en route to their final destinations, including Cassini in 1999, and Juno in 2013. Cassini’s return caused a bit of a stir as it has a plutonium-powered RTG aboard, though Earth and its inhabitants were never in danger. A nuclear RTG actually reentered during the return of Apollo 13, with no release of radioactive material. Meant for the ALSEP science package on the surface of the Moon, it was deposited on the reentry of the Lunar Module over the Marinas Trench in the South Pacific. And no, Hayabusa-2 carries no radioactive material, and in any event, it’s missing the Earth by about a quarter of its girth.

The successor to the Hayabusa (‘Peregrine Falcon’ in Japanese) mission which carried out a historic asteroid sample return from 25143 Itokawa in 2010, Hayabusa-2 launched atop an H-IIA rocket from Tanegashima, Japan exactly a year ago tomorrow on a six year mission to asteroid 162173 Ryugu. This week’s Earth flyby will boost the spacecraft an additional 1.6 kilometers per second to an outbound velocity towards its target of 31.9 kilometers per second post-flyby.

Image credit: JAXA
Launch of an H-IIA rocket with Hayabusa-2. Image credit: JAXA

Like its predecessor, Hayabusa-2 is a sample return mission. Unlike the original Hayabusa, however, Hayabusa-2 is more ambitious, also carrying the MASCOT (Mobile Asteroid Surface Scout) lander and an explosive seven kilogram impactor. Hayabusa-2 will deploy a secondary camera in orbit to watch the detonation and will briefly touch down at the impact site to collect material.

If all goes as planned, Hayabusa-2 will return to Earth in late 2020.

NASA has its own future asteroid sample return mission planned, named OSIRIS-REx. This mission will launch in September of next year to rendezvous with asteroid 101955 Bennu in September 2019 and return to Earth in September 2023.

An artist's conception on Hayabusa 2 at asteroid . Image credit: JAXA
An artist’s conception on Hayabusa 2 at asteroid 162173 Ryugu. Image credit: JAXA

We’re entering the golden age of asteroid exploration, for sure. And this all comes about as the U.S. authorized asteroid mining just last week (or at least, as stated, ‘asteroid utilization’) under the controversial U.S. Commercial Space Launch Competitiveness Act. But the original Hayabusa mission brought back mere micro-meter-sized dust grains, highlighting just how difficult asteroid mining is using present technology…

Perhaps, for now, its more cost effective to simply wait for the asteroids to come to us as meteorites and just scoop ’em up. We’ll be keeping an eye out over the next few days for images of Hayabusa-2 as it speeds by, and more postcards of the Earth-Moon system from the spacecraft as it heads towards its 2018 rendezvous with destiny.

Orion Gets Beefed Up, Silver-Metallic Thermal Protection Coating for Next Flight on EM-1

According to a new study, EDLS hardware that has been jettisoned on Mars could create problems for future missions to the same landing sites. Credit: NASA
On future missions, a silver, metallic-based thermal control coating will be bonded to the Orion crew module’s back shell tiles.  Credit: NASA
On future missions, a silver, metallic-based thermal control coating will be bonded to the Orion crew module’s back shell tiles. Credit: NASA

In the wake of NASA’s supremely successful inaugural test flight of the Orion deep space capsule on the EFT-1 mission in Dec. 2014, NASA is beefing up the critical thermal protection system (TPS) that will protect astronauts from the searing heats experienced during reentry as the human rated vehicle plunges through the Earth’s atmosphere after returning from ambitious expeditions to the Moon and beyond.

Based in part on lessons learned from EFT-1, engineers are refining Orion’s heat shield to enhance the design, ease manufacturing procedures and significantly strengthen is heat resistant capabilities for the far more challenging space environments and missions that lie ahead later this decade and planned further out in the future as part of NASA’s agency-wide ‘Journey to Mars’ initiative to send humans to the Red Planet in the 2030s.

On all future flights starting with Exploration Mission 1 (EM-1), the Orion crew module must Continue reading “Orion Gets Beefed Up, Silver-Metallic Thermal Protection Coating for Next Flight on EM-1”

First Mirror Installed on NASA’s Webb Telescope, Final Assembly Phase Starts

The James Webb Space Telescope team successfully installed the first flight mirror onto the telescope structure at NASA's Goddard Space Flight Center in Greenbelt, Maryland. Credits: NASA/Chris Gunn
The James Webb Space Telescope team successfully installed the first flight mirror onto the telescope structure at NASA's Goddard Space Flight Center in Greenbelt, Maryland.  Credits: NASA/Chris Gunn
The James Webb Space Telescope team successfully installed the first flight mirror onto the telescope structure at NASA’s Goddard Space Flight Center in Greenbelt, Maryland. Credits: NASA/Chris Gunn
Story/photos updated

After years of construction, the first of 18 primary flight mirrors has been installed onto NASA’s James Webb Space Telescope (JWST) at the agency’s Goddard Space Flight Center in Greenbelt, Maryland, signifying the start of the final assembly phase for the mammoth observatory that will eventually become the most powerful telescope ever sent to space.

The milestone first mirror installation was achieved this week just ahead of the Thanksgiving holiday as the engineering team, working inside the massive clean room at NASA Goddard, used a robotic arm to precisely lift and lower the gold coated mirror into place on the observatory’s critical mirror holding backplane assembly.

Each of the 18 hexagonal-shaped primary mirror segments Continue reading “First Mirror Installed on NASA’s Webb Telescope, Final Assembly Phase Starts”

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

The first RS-25 flight engine, No. 2059, is placed on the A-1 Test Stand at Stennis Space Center, Miss. The engines were built by Aerojet Rocketdyne and are being tested in 2015 and 2016 to certify them to fly on NASA’s new Space Launch System (SLS) rocket. SLS-1 will launch on its first uncrewed mission in 2018. Credit: NASA

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

Aerojet Rocketdyne was awarded a NASA contract to reopen the production lines for the RS-25 powerplant and develop and manufacture a certified engine for use in NASA’s SLS rocket. The contract spans from November 2015 through Sept. 30, 2024.

The SLS is the most powerful rocket the world has ever seen and will loft astronauts in the Orion capsule on missions back to the Moon by around 2021, to an asteroid around 2025 and then beyond on a ‘Journey to Mars’ in the 2030s – NASA’s overriding and agency wide goal. The first unmanned SLS test flight is slated for late 2018.

The core stage (first stage) of the SLS will initially be powered by four existing RS-25 engines, recycled and upgraded from the shuttle era, and a pair of five-segment solid rocket boosters that will generate a combined 8.4 million pounds of liftoff thrust, making it the world’s most powerful rocket ever.

The newly awarded RS-25 engine contract to Sacramento, California based Aerojet Rocketdyne is valued at 1.16 Billion and aims to “modernize the space shuttle heritage engine to make it more affordable and expendable for SLS,” NASA announced on Nov. 23. NASA can also procure up to six new flight worthy engines for later launches.

“SLS is America’s next generation heavy lift system,” said Julie Van Kleeck, vice president of Advanced Space & Launch Programs at Aerojet Rocketdyne, in a statement.

“This is the rocket that will enable humans to leave low Earth orbit and travel deeper into the solar system, eventually taking humans to Mars.”

The lead time is approximately 5 or 6 years to build and certify the first new RS-25 engine, Van Kleek told Universe Today in an interview. Therefore NASA needed to award the contract to Aerojet Rocketdyne now so that its ready when needed.

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
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

The RS-25 is actually an upgraded version of former space shuttle main engines (SSMEs) originally built by Aerojet Rocketdyne.

The reusable engines were used with a 100% success rate during NASA’s three decade-long Space Shuttle program to propel the now retired shuttle orbiters to low Earth orbit.

Atlantis rolls over  from the Orbiter Processing Facility (OPF-1, at right)  processing hanger to the Vehicle Assembly Building (VAB, at left) at KSC for the STS-135 mission.  Credit: Ken Kremer
Space Shuttles were powered by a trio of Space Shuttle Main Engines (SSMEs) now recycled and upgraded as RS-25 engines for SLS. Atlantis rolls over from the Orbiter Processing Facility (OPF-1, at right) processing hanger to the Vehicle Assembly Building (VAB, at left) at KSC for the STS-135 mission. Credit: Ken Kremer

Those same engines are now being modified for use by the SLS on missions to deep space starting in 2018.

But NASA only has an inventory of 16 of the RS-25 engines, which is sufficient for a maximum of the first four SLS launches only. Although they were reused numerous times during the shuttle era, they will be discarded after each SLS launch.

During a 535-second test on August 13, 2015, operators ran the Space Launch System (SLS) RS-25 rocket engine through a series of tests at different power levels to collect engine performance data on the A-1 test stand at NASA's Stennis Space Center near Bay St. Louis, Mississippi.  Credit: NASA
During a 535-second test on August 13, 2015, operators ran the Space Launch System (SLS) RS-25 rocket engine through a series of tests at different power levels to collect engine performance data on the A-1 test stand at NASA’s Stennis Space Center near Bay St. Louis, Mississippi. Credit: NASA

And since the engines cannot be recovered and reused as during the shuttle era, a brand new set of RS-25s will have to be manufactured from scratch.

Therefore, the engine manufacturing process can and will be modernized and significantly streamlined – using fewer part and welds – to cut costs and improve performance.

“The RS-25 engines designed under this new contract will be expendable with significant affordability improvements over previous versions,” added Jim Paulsen, vice president, Program Execution, Advanced Space & Launch Programs at Aerojet Rocketdyne. “This is due to the incorporation of new technologies, such as the introduction of simplified designs; 3-D printing technology called additive manufacturing; and streamlined manufacturing in a modern, state-of-the-art fabrication facility.”

“The new engines will incorporate simplified, yet highly reliable, designs to reduce manufacturing time and cost. For example, the overall engine is expected to simplify key components with dramatically reduced part count and number of welds. At the same time, the engine is being certified to a higher operational thrust level,” says Aerojet Rocketdyne.

The existing stock of 16 RS-25s are being upgraded for use in SLS and also being run through a grueling series of full duration hot fire test firings to certify them for flight, as I reported previously here at Universe Today.

Among the RS-25 upgrades is a new engine controller specific to SLS. The engine controller functions as the “brain” of the engine, which checks engine status, maintains communication between the vehicle and the engine and relays commands back and forth.

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

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

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

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

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

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

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

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

Ken Kremer

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Learn more about SLS, Orion, SpaceX, Orbital ATK Cygnus, ISS, ULA Atlas rocket, Boeing, Space Taxis, Mars rovers, Antares, NASA missions and more at Ken’s upcoming outreach events:

Dec 1 to 3: “Orbital ATK Atlas/Cygnus launch to the ISS, ULA, SpaceX, SLS, Orion, Commercial crew, Curiosity explores Mars, Pluto and more,” Kennedy Space Center Quality Inn, Titusville, FL, evenings

Dec 8: “America’s Human Path Back to Space and Mars with Orion, Starliner and Dragon.” Amateur Astronomers Assoc of Princeton, AAAP, Princeton University, Ivy Lane, Astrophysics Dept, Princeton, NJ; 7:30 PM.

NASA Orders First Commercial Crew Mission to Space Station from SpaceX

SpaceX Crew Dragon will blast off atop a Falcon 9 rocket from Launch Pad 39A at NASA's Kennedy Space Center in Florida for missions to the International Space Station. Pad 39A is undergoing modifications by SpaceX to adapt it to the needs of the company's Falcon 9 and Falcon Heavy rockets, which are slated to lift off from the historic pad in the near future. A horizontal integration facility (right) has been constructed near the perimeter of the pad where rockets will be processed for launch prior of rolling out to the top of the pad structure for liftoff. Credit: Ken Kremer/Kenkremer.com
SpaceX Crew Dragon will blast off atop a Falcon 9 rocket from Launch Pad 39A at NASA's Kennedy Space Center in Florida  for missions to the International Space Station. Pad 39A is  undergoing modifications by SpaceX to adapt it to the needs of the company's Falcon 9 and Falcon Heavy rockets, which are slated to lift off from the historic pad in the near future. A horizontal integration facility (right) has been constructed near the perimeter of the pad where rockets will be processed for launch prior of rolling out to the top of the pad structure for liftoff. Credit: Ken Kremer/Kenkremer.com
SpaceX Crew Dragon will blast off atop a Falcon 9 rocket from Launch Pad 39A at NASA’s Kennedy Space Center in Florida for missions to the International Space Station. Pad 39A is undergoing modifications by SpaceX to adapt it to the needs of the company’s Falcon 9 and Falcon Heavy rockets, which are slated to lift off from the historic pad in the near future. A horizontal integration facility (right) has been constructed near the perimeter of the pad where rockets will be processed for launch prior of rolling out to the top of the pad structure for liftoff. Credit: Ken Kremer/Kenkremer.com

Restoring America’s ability to once again launch US astronauts to the International Space Station (ISS) from US soil on US rockets took another significant step forward when NASA ordered the first the agency’s first commercial crew rotation mission from the Hawthorne, California based-company SpaceX. NASA and SpaceX hope that the blastoff with a crew of up to four astronauts will take place by late 2017.

The new Nov. 20 award from NASA’s Commercial Crew Program (CCP) office to launch the SpaceX Crew Dragon capsule follows up on an earlier commercial crew rotation mission award this past May to the Boeing Company of Houston to launch its CST-100 Starliner astronaut crew capsule to the ISS.

Since the retirement of NASA’s Space Shuttle orbiters in Continue reading “NASA Orders First Commercial Crew Mission to Space Station from SpaceX”