The dual Atlas V rocket engines roar to life on a United Launch Alliance Atlas V rocket at Cape Canaveral Air Force Station's Space Launch Complex 41. The launch vehicle will boost NASA's Tracking and Data Relay Satellite, or TDRS-L, spacecraft to Earth orbit. Liftoff was at 9:33 p.m. EST on Jan. 23, 2014. Credit: NASA
The dual Atlas V rocket engines roar to life on a United Launch Alliance Atlas V rocket at Cape Canaveral Air Force Station’s Space Launch Complex 41. The launch vehicle will boost NASA’s Tracking and Data Relay Satellite, or TDRS-L, spacecraft to Earth orbit. Liftoff was at 9:33 p.m. EST on Jan. 23, 2014.
Credit: NASA Story updated[/caption]
A spectacular nighttime blastoff lit up the evening skies for hundreds of miles around the Florida Space coast on a mission that sent a critical NASA communications relay satellite to orbit this evening, Jan. 23.
NASA’s huge Tracking and Data Relay Satellite L (TDRS-L) is now safely in orbit following tonight’s successful launch aboard a United Launch Alliance Atlas V rocket from Cape Canaveral Air Force Station in Florida.
The Atlas V rocket was launched at 9:33 p.m. EST from Space Launch Complex 41 into crystal clear skies that gave excited spectators an uncommonly long and stunning launch spectacle that was well worth the wait.
The 3.8 ton TDRS-L satellite will become part of a network providing high-data-rate communications to the International Space Station (ISS), Hubble Space Telescope, launch vehicles and a host of other research spacecraft that relay absolutely critical flight, telemetry and science data.
Water reflection shot of NASA TDRS-L satellite launch aboard Atlas V rocket on Jan. 23, 2014. Credit: Walter Scriptunas II – www.scriptunasimages.com
The ISS, Hubble and all these other spacecraft could not function without the TDRS network of relay satellites.
Liftoff of NASA”s TDRS-L atop Atlas V rocket on Jan. 23, 2014 from CAPE CANAVERAL, Fla. Credit: NASA
The TDRS-L satellite will also be used to track and relay vital information for the maiden launch of NASA’s next generation Orion human spaceflight capsule slated for Fall 2014.
“TDRS-L and the entire TDRS fleet provide a vital service to America’s space program by supporting missions that range from Earth-observation to deep space discoveries,” said NASA Administrator Charles Bolden.
“TDRS also will support the first test of NASA’s new deep space spacecraft, the Orion crew module, in September. This test will see Orion travel farther into space than any human spacecraft has gone in more than 40 years.”
A United Launch Alliance (ULA) Atlas V rocket successfully launched NASA’s Tracking and Data Relay Satellite (TDRS-L) payload at 9:33 p.m. EST today from Space Launch Complex-41. Credit: Ben Cooper/Launch photography
TDRS-L arrived in geosynchronous transfer orbit about two hours after liftoff. It will orbit at an altitude of 22,300 miles.
The venerable Atlas V rocket is one of the most reliable and well built rockets in the world.
Indeed the Atlas V has been entrusted to launch many high value missions for NASA and the Defense Department- such as Curiosity, JUNO and the X-37 B.
Clear of the lightning wires, the Atlas 5-401 accelerates to orbit. Credit: nasatech.net
The last Atlas V launch from the Cape occurred in November 2013 and sent NASA’s MAVEN Mars orbiter on a voyage to the Red Planet.
NASA’s Mars bound MAVEN spacecraft launches atop Atlas V booster at 1:28 p.m. EST from Space Launch Complex 41 at Cape Canaveral Air Force Station on Nov. 18, 2013. Image taken from the roof of the Vehicle Assembly Building (VAB) at NASA’s Kennedy Space Center. Credit: Ken Kremer/kenkremer.com
And the two stage rocket is being man-rated right now to launch humans to low Earth orbit in the near future.
The Atlas V has been chosen to launch two of the upcoming astronaut ‘space taxis’ as part of NASA’s commercial crew initiative to launch human crews to the International Space Station.
Just today, Sierra Nevada Corp announced that their Dream Chaser mini shuttle will launch to orbit on its first flight on Nov. 1, 2016.
TDRS-L is the 12th in this series of communications satellites.
It is identical to the TDRS-K spacecraft launched in 2013, which was the first of the third generation of TDRS satellites.
They were built by Boeing Space and Intelligence Systems of El Segundo, Calif., and have a 15 year design lifetime.
NASA will now conduct a three month in orbit checkout.
TDRS-M, the next spacecraft in this series, is on track to be ready for launch in late 2015.
TDRS-L awaits launch atop Atlas V rocket. Credit: Mike Killian/mikekillianphotography.com
This is the third generation of TDRS satellites.
“The TDRS fleet began operating during the space shuttle era with the launch of TDRS-1 in 1983. Of the 11 TDRS spacecraft placed in service to date, eight still are operational. Four of the eight have exceeded their design life,” said NASA.
The Atlas V launched in the 401 configuration vehicle, which includes a 4-meter diameter payload fairing and no solid rocket motors. The first stage was powered by the RD AMROSS RD-180 engine. The Centaur upper stage was powered by a single Aerojet Rocketdyne RL10A-4 engine.
Stay tuned here for Ken’s continuing Orion, Chang’e-3, Orbital Sciences, SpaceX, commercial space, LADEE, Mars and more news.
Pictured in Astrotech’s payload processing facility on 3 January 2014, TDRS-L resembles an enormous insect and will form the 12th member of NASA’s Tracking and Data Relay Satellite family. Photo Credit: Mike Killian Photography/AmericaSpacePhoto Credit: Alan Walters / AmericaSpace
Engineers prepare Orion’s service module for installation of the fairings that will protect it during launch this fall when Orion launches on its first mission. The service module, along with its fairings, is now complete. Credit: NASA
Engineers prepare Orion’s service module for installation of the fairings that will protect it during launch this fall when Orion launches on its first mission. The service module, along with its fairings, is now complete. Credit: NASA
Story Updated[/caption]
2014 is the Year of Orion.
Orion is NASA’s next human spaceflight vehicle destined for astronaut voyages beyond Earth and will launch for the first time later this year on its inaugural test flight from Cape Canaveral, Florida.
The space agency is rapidly pressing forward with efforts to finish building the Orion crew module slated for lift off this Fall on the unmanned Exploration Flight Test – 1 (EFT-1) mission.
NASA Administrator Charles Bolden and science chief Astronaut John Grunsfeld discuss NASA’s human spaceflight initiatives backdropped by the service module for the Orion crew capsule being assembled at the Kennedy Space Center. Credit: Ken Kremer/kenkremer.com
The Orion module stack is comprised of three main elements – the Launch Abort System (LAS) on top, the crew module (CM) in the middle and the service module (SM) on the bottom.
With the completion of the service module, two thirds of the Orion EFT-1 mission stack are now compete.
LAS assembly was finalized in December.
The crew module is in the final stages of construction and completion is due by early spring.
Orion is being manufactured at NASA’s Kennedy Space Center (KSC) inside a specially renovated high bay in the Operations and Checkout Building (O&C).
“We are making steady progress towards the launch in the fall,” said NASA Administrator Charles Bolden at a media briefing back dropped by the Orion service module inside the O&C facility.
“It’s very exciting because it signals we are almost there getting back to deep space and going much more distant than where we are operating in low Earth orbit at the ISS.”
“And I’m very excited for the young people who will have an opportunity to fly Orion,” Bolden told me in the O&C.
Lockheed Martin is the prime contractor for Orion under terms of a contract from NASA.
Orion is NASA’s first spaceship designed to carry human crews on long duration flights to deep space destinations beyond low Earth orbit, such as asteroids, the Moon, Mars and beyond.
The inaugural flight of Orion on the unmanned Exploration Flight Test – 1 (EFT-1) mission is on schedule to blast off from the Florida Space Coast in mid September 2014 atop a Delta 4 Heavy booster, Scott Wilson, NASA’s Orion Manager of Production Operations at KSC, told Universe Today during a recent interview at KSC.
Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) mock up stack inside the transfer aisle of the Vehicle Assembly Building (VAB) at the Kennedy Space Center (KSC) in Florida. Service Module at bottom. Credit: Ken Kremer/kenkremer.com
Orion is currently under development as NASA’s next generation human rated vehicle to replace the now retired space shuttle.
Concurrently, NASA’s commercial crew initiative is fostering the development of commercial space taxi’s to ferry US astronauts to low Earth orbit and the International Space Station (ISS).
Get the details in my interview with SpaceX CEO Elon Musk about his firm’s Dragon ‘space taxi’ launching aboard the SpaceX upgraded Falcon 9 booster – here.
The two-orbit, four- hour EFT-1 flight will lift the Orion spacecraft and its attached second stage to an orbital altitude of 3,600 miles, about 15 times higher than the International Space Station (ISS) – and farther than any human spacecraft has journeyed in 40 years.
The crew module rests atop the service module, similar to the Apollo Moon landing program architecture.
Orion service module assembly in the Operations and Checkout facility at Kennedy Space Center. Credit: Ken Kremer/kenkremer.com
The SM provides in-space power, propulsion capability, attitude control, thermal control, water and air for the astronauts.
For the EFT-1 flight, the SM is not fully outfitted. It is a structural representation simulating the exact size and mass.
In a significant difference from Apollo, Orion is equipped with a trio of massive fairings that encase the SM and support half the weight of the crew module and the launch abort system during launch and ascent. The purpose is to improve performance by saving weight from the service module, thus maximizing the vehicles size and capability in space.
All three fairings are jettisoned at an altitude of 100 miles up when they are no longer need to support the stack.
The fairings that will protect it during launch are added to Orion’s service module at the Operations and Checkout facility at Kennedy Space Center. Credit: NASA
On the next Orion flight in 2017, the service module will be manufactured built by the European Space Agency (ESA).
“When we go to deep space we are not going alone. It will be a true international effort including the European Space Agency to build the service module,” said Bolden.
The new SM will be based on components from ESA’s Automated Transfer Vehicle (ATV) which is an unmanned resupply spacecraft used to deliver cargo to the ISS.
A key upcoming activity for the CM is installation of the thermal protection system, including the heat shield.
The heat shield is the largest one ever built. It arrived at KSC last month loaded inside NASA’s Super Guppy aircraft while I observed. Read my story – here.
The 2014 EFT-1 test flight was only enabled by the extremely busy and productive year of work in 2013 by the Orion EFT-1 team.
“There were many significant Orion assembly events ongoing on 2013” said Larry Price, Orion deputy program manager at Lockheed Martin, in an interview with Universe Today at Lockheed Martin Space Systems in Denver.
“This includes the heat shield construction and attachment, power on, installing the plumbing for the environmental and reaction control system, completely outfitting the crew module, attached the tiles and building the service module which finally leads to mating the crew and service modules (CM & SM) in early 2014,” Price told me.
Orion was originally planned to send American astronauts back to Moon – until Project Constellation was cancelled by the Obama Administration.
Now with Orion moving forward and China’s Yutu rover trundling spectacularly across the Moon, one question is which country will next land humans on the Moon – America or China?
Read my story about China’s manned Moon landing plans – here.
Stay tuned here for Ken’s continuing Orion, Chang’e-3, Orbital Sciences, SpaceX, commercial space, LADEE, Mars and more news.
Orion schematic. Credit: NASANASA Administrator Charles Bolden meets the media including Ken Kremer/Universe Today to discuss NASA’s human spaceflight initiatives and Orion crew capsule being assembled at the Kennedy Space Center. Credit: Urijan Poerink
Technicians work inside the Orion crew module being built at Kennedy Space Center to prepare it for its first power on. Turning the avionics system inside the capsule on for the first time marks a major milestone in Orion’s final year of preparations before its first mission, Exploration Flight Test 1
Credit: Lockheed Martin
Technicians work inside the Orion crew module being built at Kennedy Space Center to prepare it for its first power on. Turning the avionics system inside the capsule on for the first time marks a major milestone in Orion’s final year of preparations before its first mission, Exploration Flight Test 1. Credit: Lockheed Martin Story and imagery updated[/caption]
KENNEDY SPACE CENTER, FL – Orion, the first NASA spaceship that will ever carry Earthlings to deep space destinations, has at last been “powered on” for the first time at the manufacturing facility at the Kennedy Space Center (KSC) where it’s the centerpiece of a beehive humming 24/7 with hi tech processing activities in all directions.
“Power On” marks a major milestone ahead of the maiden space bound Orion test flight dubbed “EFT-1” – now at T-Minus 1 year and counting!
NASA and prime contractor Lockheed Martin recently granted Universe Today an exclusive in depth inspection tour of the impressive Orion EFT-1 crew module, service module and associated hardware destined for the crucial unmanned test flight slated for liftoff from Cape Canaveral in September 2014.
“We are moving fast!” said Jules Schneider, Orion Project manager for Lockheed Martin at KSC, during an exclusive interview with Universe Today as we spoke beside the Orion EFT-1 spacecraft inside the clean room.
“We are bringing Orion to life. Lots of flight hardware has now been installed.”
Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) mock up stack inside the transfer aisle of the Vehicle Assembly Building (VAB) at the Kennedy Space Center (KSC) in Florida. Powerful quartet of LAS abort motors will fire in case of launch emergency to save astronauts lives. Credit: Ken Kremer/kenkremer.com
“We are working 24 hours a day, 7 days a week,” Schneider told me.
Some 200 people are actively employed on building Orion by Lockheed Martin at the Kennedy Space Center.
“There are many significant Orion assembly events ongoing this year,” said Larry Price, Orion deputy program manager at Lockheed Martin, in an interview with Universe Today at Lockheed Space Systems in Denver.
“This includes the heat shield construction and attachment, power on, installing the plumbing for the environmental and reaction control system, completely outfitting the crew module, attached the tiles, building the service module and finally mating the crew and service modules (CM & SM),” Price told me.
I have been very fortunate to periodically visit Orion up close over the past year and half to evaluate the testing and assembly progress inside the Operations and Checkout Building at KSC where the vehicle is now rapidly coming together, since the bare bones pressure vessel arrived to great fanfare in June 2012.
For the first time Orion looked to my eyes like a real spaceship, rather than the backbone shell outfitted with hundreds of important test harnesses, strain gauges and wiring to evaluate its physical and structural integrity.
Technicians work inside the Orion crew module being built at Kennedy Space Center to prepare it for its first power on. Turning the avionics system inside the capsule on for the first time marks a major milestone in Orion’s final year of preparations before its first mission, Exploration Flight Test 1. Credit: Lockheed Martin
Engineers and technicians at KSC have removed the initial pressure testing gear and are now installing all the flight systems and equipment – such as avionics, instrumentation, flight computers, thrusters, wiring, plumbing, heat shield and much more – required to transform the initial empty shell into a fully functioning spacecraft.
“The Orion skeleton was here before. Now we are putting in all of the other systems,” Schneider explained to me.
“We are really busy.”
“So far over 66,000 Orion parts have been shipped to KSC from over 40 US states,” Price explained.
The heat shield was due to arrive soon and technicians were drilling its attachment ring holes as I observed the work in progress.
“The propulsion, environmental control and life support systems are now about 90% in. The ammonia and propylene glycol loops for the thermal control system are in. Many of the flight harnesses are installed.”
“All of the reaction control thrusters are in – fueled by hydrazine – as well as the two hydrazine tanks and a helium tank. Altogether there are 12 hydrazine pods with two thrusters each,” Schneider elaborated.
The power distribution unit (PDU) – which basically functions as Orion’s computer brains – was installed just prior to my visit. All four PDU’s – which issue commands to the vehicle – were built by Honeywell.
Technicians were actively installing fiber optic and coaxial cables as I watched. They also were conducting leak tests on the environmental control coolant (ECLS) systems which had to be completed before the ‘power on’ testing could begin – in order to cool the avionics systems.
Thermal protection system (TPS) tiles were being bonded to the back panels which ring Orion. The TPS panels get attached early in 2014.
“This is real stuff,” said Schneider gleefully.
Inside the Operations and Checkout Building high bay at NASA’s Kennedy Space Center in Florida, a tile technician works on a section of thermal protection system tiles seen by Universe Today and that will be installed on the Orion crew module. Credit: NASA/Dimitri Gerondidakis
NASA says that “the preliminary data indicate Orion’s vehicle management computer, as well as its innovative power and data distribution system — which use state-of-the-art networking capabilities — performed as expected” during the initial crew module power on.
About two months or so of power on functional testing of various systems will follow.
Just like the configuration used in the Apollo era, the Orion crew module will sit atop a service module – and that work is likewise moving along at a rapid clip.
“The Orion service module (SM) is also almost complete,” Schneider said as he showed me the service module structure.
“Structurally the SM is 90% done. The active thermal control system is in and all the fluid systems are welded in and pressure tested.”
Cutaway diagram of Orion components including crew module and service module and adapters. Credit: NASA
Orion EFT-1 will blastoff atop a mammoth United Launch Alliance Delta IV Heavy rocket – the most powerful booster in America’s arsenal since the shuttle’s retirement in 2011.
The crew module and service module (CM/SM) will be mated inside the O&C and then be placed onto a mission adapter that eventually attaches to the top of the Delta IV Heavy booster.
They will be mated at the exact same spot in the O&C Building where the Apollo era command and service modules were stacked four decades ago.
Currently, the schedule calls for the Orion CM/SM stack to roll out to Kennedy’s Payload Hazardous Services Facility (PHSF) for servicing and fueling late this year, said Larry Price.
After that the CM/SM stack is transported to the nearby Launch Abort System Facility (LASF) for mating to the emergency Launch Abort System (LAS).
All that work could be done around March 2014 so that ground operations preparing for launch can commence, according to Price.
“In March 2014 we’ll be ready for ground ops. The normal launch processing flow starts in June 2014 leading to Orion’s launch from pad 37 in September 2014.”
“It’s very exciting and a tribute to the NASA and contractor teams,” Price said.
The 2014 uncrewed flight will be loaded with a wide variety of instruments to evaluate how the spacecraft behaves during launch, in space and then through the searing heat of reentry.
The two-orbit, four- hour flight will lift the Orion spacecraft and its attached second stage to an orbital altitude of 3,600 miles, about 15 times higher than the International Space Station (ISS) – and farther than any human spacecraft has journeyed in 40 years.
An artist concept shows Orion as it will appear in space for the Exploration Flight Test-1 attached to a Delta IV second stage. Credit: NASA
Although the mission will only last a few hours it will be high enough to send the vehicle plunging back into the atmosphere and a Pacific Ocean splashdown to test the craft and its heat shield at deep-space reentry speeds of 20,000 mph and endure temperatures of 4,000 degrees Fahrenheit – like those of the Apollo moon landing missions.
The Orion EFT-1 mission will end with a splashdown in the Pacific Ocean. During the stationary recovery test of Orion at Norfolk Naval Base on Aug. 15, 2013, US Navy divers attached tow lines and led the test capsule to a flooded well deck on the USS Arlington. Credit: Ken Kremer/kenkremer.com.
The EFT-1 mission will provide engineers with critical data about Orion’s heat shield, flight systems and capabilities to validate designs of the spacecraft, inform design decisions, validate existing computer models and guide new approaches to space systems development. All these measurements will aid in reducing the risks and costs of subsequent Orion flights before it begins carrying humans to new destinations in the solar system.
“The Orion hardware and the Delta IV Heavy booster for the EFT-1 launch are on target for launch in 2014,” Scott Wilson, NASA’s Orion Manager of Production Operations, told Universe Today in an interview.
Learn more about Orion, MAVEN, Mars rovers and more at Ken’s upcoming presentations
Nov 14-19: “MAVEN Mars Launch and Curiosity Explores Mars, Orion and NASA’s Future”, Kennedy Space Center Quality Inn, Titusville, FL, 8 PM
Dec 11: “Curiosity, MAVEN and the Search for Life on Mars”, “LADEE & Antares ISS Launches from Virginia”, Rittenhouse Astronomical Society, Franklin Institute, Phila, PA, 8 PM
Orion EFT-1 capsule under construction inside the Structural Assembly Jig at the Operations and Checkout Building (O & C) at the Kennedy Space Center (KSC); Jules Schneider, Orion Project Manager for Lockheed Martin and Ken Kremer, Universe Today. Credit: Ken Kremer – kenkremer.com
NASA astronaut Randy Bresnik prepares to enter the CST-100 spacecraft, which was built inside The Boeing Company's Houston Product Support Center. Credit: NASA/Robert Markowitz
A pair of NASA astronauts donned their spacesuits for key fit check evaluations inside a test version of the Boeing Company’s CST-100 commercial ‘space taxi’ which was unveiled this week for the world’s first glimpse of the cabin’s interior.
Boeing is among a trio of American aerospace firms, including SpaceX and Sierra Nevada Corp, seeking to restore America’s capability to fly humans to Earth orbit and the space station using seed money from NASA’s Commercial Crew Program (CCP).
Astronauts Serena Aunon and Randy Bresnik conducted a day long series of technical evaluations inside a fully outfitted, full scale mock up of the CST-100, while wearing NASA’s iconic orange launch-and-entry flight suits from the space shuttle era.
During the tests, Boeing technicians monitored the astronauts ergonomic ability to work in the seats and move around during hands on use of the capsules equipment, display consoles and storage compartments.
The purpose of the testing at Boeing’s Houston Product Support Center is to see what works well and what needs modifications before fixing the final capsule design for construction.
“It’s an upgrade,” said astronaut Serena Aunon at the evaluation. “It is an American vehicle, of course it is an upgrade.”
This is an interior view of The Boeing Company’s CST-100 spacecraft, which features LED lighting and tablet technology. Image Credit: NASA/Robert Markowitz
Former NASA Astronaut Chris Ferguson, the commander of the final shuttle flight (STS-135) by Atlantis, is leading Boeing’s test effort as the director of Boeing’s Crew and Mission Operations.
“These are our customers. They’re the ones who will take our spacecraft into flight, and if we’re not building it the way they want it we’re doing something wrong,” said Ferguson.
“We’ll probably make one more go-around and make sure that everything is just the way they like it.”
The CST-100 is designed to carry a crew of up to 7 astronauts, or a mix of cargo and crew, on missions to low-Earth orbit (LEO) and the International Space Station (ISS) around the middle of this decade.
Although it resembles Boeing’s Apollo-era capsules from the outside, the interior employs state of the art modern technology including sky blue LED lighting and tablet technology.
Check out this video showing the astronauts and engineers during the CST-100 testing
Nevertheless Boeing’s design goal is to keep the flight technology as simple as possible.
“What you’re not going to find is 1,100 or 1,600 switches,” said Ferguson. “When these guys go up in this, they’re primary mission is not to fly this spacecraft, they’re primary mission is to go to the space station for six months. So we don’t want to burden them with an inordinate amount of training to fly this vehicle. We want it to be intuitive.”
The CST-100 crew transporter will fly to orbit atop the venerable Atlas V rocket built by United Launch Alliance (ULA) from Launch Complex 41 on Cape Canaveral Air Force Station in Florida.
The CST-100 crew capsule awaits liftoff aboard an Atlas V launch vehicle at Cape Canaveral in this artist’s concept. Credit: Boeing
Boeing is aiming for an initial three day manned orbital test flight of the CST-100 during 2016, says John Mulholland, Boeing vice president and program manger for Commercial Programs.
The 1st docking mission to the ISS would follow in 2017 – depending on the very uncertain funding that Congress approves for NASA.
The Atlas V was also chosen to launch one of Boeing’s commercial crew competitors, namely the Dream Chaser mini shuttle built by Sierra Nevada Corp.
Boeing CST-100 capsule early mock-up, interior view. Credit: Ken Kremer – kenkremer.com
NASA’s CCP program is fostering the development of the CST-100 as well as the SpaceX Dragon and Sierra Nevada Dream Chaser to replace America’s capability to launch humans to space that was lost following the retirement of NASA’s space shuttle orbiters two years ago in July 2011.
Since 2011, every American astronaut has been 100% dependent on the Russians and their Soyuz capsule to hitch a ride to the ISS.
“We pay one of our [ISS] partners, the Russians, $71 million a seat to fly,” says Ed Mango, CCP’s program manager. “What we want to do is give that to an American company to fly our crews into space.”
Simultaneously NASA and its industry partners are designing and building the Orion crew capsule and SLS heavy lift booster to send humans to the Moon and deep space destinations including Near Earth Asteroids and Mars.
NASA Orion spacecraft blasts off atop 1st Space Launch System rocket in 2017 - attached to European provided service module – on an enhanced m mission to Deep Space where an asteroid could be relocated as early as 2021. Credit: NASA
NASA Orion spacecraft blasts off atop 1st Space Launch System rocket in 2017 – attached to European provided service module – on an ambitious mission to explore Deep Space some 40,000 miles beyond the Moon, where an asteroid could be relocated as early as 2021. Credit: NASA Story updated with further details[/caption]
NASA managers have announced a bold new plan to significantly alter and upgrade the goals and complexity of the 1st mission of the integrated Orion/Space Launch System (SLS) human exploration architecture – planned for blastoff in late 2017.
The ambitious first flight, called Exploration Mission 1 (EM-1), would be targeted to send an unpiloted Orion spacecraft to a point more than 40,000 miles (70,000 kilometers) beyond the Moon as a forerunner supporting NASA’s new Asteroid Redirect Initiative – recently approved by the Obama Administration.
The EM-1 flight will now serve as an elaborate harbinger to NASA’s likewise enhanced EM-2 mission, which would dispatch a crew of astronauts for up close investigation of a small Near Earth Asteroid relocated to the Moon’s vicinity.
Orion crew module separates from Space Launch System (SLS) upper stage. Credit: NASA
Until recently NASA’s plan had been to launch the first crewed Orion atop the 2nd SLS rocket in 2021 to a high orbit around the moon on the EM-2 mission, said NASA Associate Administrator Lori Garver in an prior interview with me at the Kennedy Space Center.
Concept of NASA spacecraft with Asteroid capture mechanism deployed to redirect a small space rock to a stable lunar orbit for later study by astronauts aboard Orion crew capsule. Credit: NASA.
The enhanced EM-1 flight would involve launching an unmanned Orion, fully integrated with the Block 1 SLS to a Deep Retrograde Orbit (DRO) near the moon, a stable orbit in the Earth-moon system where an asteroid could be moved to as early as 2021.
Orion’s mission duration would be nearly tripled to 25 days from the original 10 days.
“The EM-1 mission with include approximately nine days outbound, three to six days in deep retrograde orbit and nine days back,” Brandi Dean, NASA Johnson Space Center spokeswoman told Universe Today exclusively.
The proposed much more technologically difficult EM-1 mission would allow for an exceptionally more vigorous work out and evaluation of the design of all flight systems for both Orion and SLS before risking a flight with humans aboard.
Asteroid Capture in Progress
A slew of additional thruster firings would exercise the engines to change orbital parameters outbound, around the moon and inbound for reentry.
The current Deep Retrograde Orbit (DRO) plan includes several thruster firings from the Orion service module, including a powered lunar flyby, an insertion at DRO, an extraction maneuver from the DRO and a powered flyby on return to Earth.
Orion would be outfitted with sensors to collect a wide variety of measurements to evaluate its operation in the harsh space environment.
“EM-1 will have a compliment of both operational flight instrumentation and development flight instrumentation. This instrumentation suite gives us the ability to measure many attributes of system functionality and performance, including thermal, stress, displacement, acceleration, pressure and radiation,” Dean told me.
The EM-1 flight has many years of planning and development ahead and further revisions prior to the 2017 liftoff are likely.
“Final flight test objectives and the exact set of instrumentation required to meet those objectives is currently under development,” Dean explained.
Orion is NASA’s next generation manned space vehicle following the retirement of NASA’s trio of Space Shuttles in 2011.
The SLS launcher will be the most powerful and capable rocket ever built by humans – exceeding the liftoff thrust of the Apollo era Moon landing booster, the mighty Saturn V.
“We sent Apollo around the moon before we landed on it and tested the space shuttle’s landing performance before it ever returned from space.” said Dan Dumbacher, NASA’s deputy associate administrator for exploration systems development, in a statement.
“We’ve always planned for EM-1 to serve as the first test of SLS and Orion together and as a critical step in preparing for crewed flights. This change still gives us that opportunity and also gives us a chance to test operations planning ahead of our mission to a relocated asteroid.”
Both Orion and SLS are under active and accelerating development by NASA and its industrial partners.
The 1st Orion capsule is slated to blast off on the unpiloted EFT-1 test flight in September 2014 atop a Delta IV Heavy rocket on a two orbit test flight to an altitude of 3,600 miles above Earth’s surface.
Technicians work on mockups of the Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) to simulate critical assembly techniques inside the Vehicle Assembly Building (VAB) at NASA’s Kennedy Space Center (KSC) in Florida for the EFT-1 mission due to liftoff in September 2014. Credit: Ken Kremer/kenkremer.com
It will then reenter Earth’s atmosphere at speeds of about 20,000 MPH (11 km/sec) and endure temperatures of 4,000 degrees Fahrenheit in a critical test designed to evaluate the performance of Orion’s heatshield and numerous spacecraft systems.
Orion EFT-1 is already under construction at the Kennedy Space Center (KSC) by prime contractor Lockheed Martin – read my earlier story here.
Integration and stacking tests with Orion’s emergency Launch Abort System are also in progress at KSC – details here.
NASA says the SLS is also in the midst of a extensive review process called the Preliminary Design Review (PDR) to ensure that all launch vehicle components and systems will achieve the specified performance targets and be completed in time to meet the 2017 launch date. The PDR will be completed later this summer.
NASA’s goal with Orion/SLS is to send humans to the Moon and other Deep Space destinations like Asteroids and Mars for the first time in over forty years since the final manned lunar landing by Apollo 17 back in 1972.
NASA Headquarters will make a final decision on upgrading the EM-1 mission after extensive technical reviews this summer.
A crane lifts the Orion EFT-1 crew module from its birdcage processing stand for transfer it to a dolly for continued assembly inside the Operations and Checkout Building high bay at NASA’s Kennedy Space Center in Florida as workers monitor progress. Orion’s first unpiloted test flight is scheduled to launch in 2014. Credit: NASA/Frankie Martin
NASA is picking up the construction pace on the inaugural space-bound Orion crew capsule at the Kennedy Space Center (KSC) in Florida – and accelerating towards blastoff on the unmanned Exploration Flight Test-1 mission (EFT-1) slated for September 2014 atop a mammoth Delta 4 Heavy Booster which will one day lead to deep space human forays to Asteroids and Mars.
Orion was at the center of an impressive and loud beehive of action packed assembly activities by technicians during my recent exclusive tour of the spacecraft to inspect ongoing progress inside the renovated Orion manufacturing assembly facility in the Operations and Checkout Building (O & C) at KSC.
“We plan to power up Orion for the first time this summer,” said Scott Wilson in an exclusive interview with Universe Today beside the Orion vehicle. Wilson is Orion’s Production Operations manager for NASA at KSC.
The Orion EFT-1 flight is a critical first step towards achieving NASA’s new goal of capturing and retrieving a Near Earth Asteroid for eventual visit by astronauts flying aboard an Orion vehicle by 2021 – if NASA’s budget request is approved.
An artist concept shows Orion as it will appear in space for the Exploration Flight Test-1 attached to a Delta IV second stage. Credit: NASA
KSC will have a leading role in NASA’s asteroid retrieval project that could occur some four years earlier than President Obama’s targeted goal of 2025 for a human journey to an asteroid.
Capturing an asteroid and dispatching astronauts aboard Orion to collect precious rock samples will aid our scientific understanding of the formation of the Solar System as well as bolster Planetary Defense strategies – the importance of which is gathering steam following the unforeseen Russian meteor strike in February which injured over 1200 people and damaged over 3000 buildings.
Dozens of highly skilled workers were busily cutting metal, drilling holes, bolting screws and attaching a wide range of mechanical and electrical components and bracketry to the Orion pressure vessel’s primary structure as Universe Today conducted a walk around of the EFT-1 capsule, Service Module and assorted assembly gear inside the O&C.
Orion EFT-1 crew cabin and full scale mural showing Orion Crew Module atop Service Module inside the O & C Building at the Kennedy Space Center, Florida. Credit: Ken Kremer/kenkremer.com
Lockheed Martin is the primary contractor for Orion. A growing number of employees hired by Lockheed and United Space Alliance (USA) are “working 2 shifts per day 7 days a week to complete the assembly work by year’s end,” said Jules Schneider, Orion Project manager for Lockheed Martin at KSC, during an exclusive interview with Universe Today.
I watched as the workers were boring hundreds of precision holes and carefully tightening the high strength steel bolts to attach the top to bottom ring segments made of titanium to the main load paths on the pressure vessel.
“We are installing lots of wiring to support ground test instrumentation for the strain gauges as well as microphones and accelerometers.”
“The simulated back shell panels are being installed now as guides,” said Wilson. “The real back shell panels and heat shield will be installed onto the structure later this year.”
“The heat shield is the biggest one ever built, 5 meters in diameter. Its bigger than Apollo and Mars Science Lab. It varies in thickness from about 1 to 3 inches depending on the expected heating.”
“We are making good progress on the Orion Service module too. The outer panels will be installed soon,” Wilson explained.
The olive green colored crew module was clamped inside the birdcage-like Structural Assembly Jig during my visit. The Jig has multiple degrees of freedom to maneuver the capsule and more easily enable the detailed assembly work.
“The technicians are installing strain gauges and secondary structure components to get it ready for the upcoming structural loads test,” said Schneider.
“After that we need to finish installing all the remaining parts of the primary structure and a significant portion of the secondary structure.”
For the next stage of processing, the EFT-1 crew module has been lifted out of the birdcage Jig and moved onto an adjacent dedicated work station for loads testing at the Operations and Checkout building.
As reported in my earlier article the Orion pressure vessel sustained three ‘hairline” cracks in the lower half of the aft bulkhead during proof pressure testing of the vessel and welds at the O & C.
I was observing as the technicians were carefully milling out the miniscule bulkhead fractures.
Workers have now installed custom built replacement brackets and reinforcing doublers on the aft bulkhead.
“We will do the protocol loads test with pressure using about 9 different load cases the vehicle will see during the EFT-1 flight. Chute deployment and jettison motor deployment is a driving load case,” said Schneider.
“We will also squeeze the capsule,” said Wilson.
“That structural loads testing of the integrated structure will take about 6 to 8 weeks. There are thousands of gauges on the vehicle to collect data,” Schneider elaborated.
“The test data will be compared to the analytical modeling to see where we are at and how well it matched the predictions – it’s like acceptance testing.”
“After we finish the structural loads tests we can than start the assembly and integration of all the other subsystems.”
“When we are done with the ground testing program then we remove all the ground test instrumentation and start installing all the actual flight systems including harnesses and instrumentation, the plumbing and everything else,” Schneider explained.
Orion hardware built by contractors and subcontractors from virtually every state all across the U.S is being delivered to KSC for installation onto EFT-1. Orion is a nationwide human spaceflight project.
Concept of Spacecraft with Asteroid Capture Mechanism Deployed. Credit: NASA.
During the unmanned Orion EFT-1 mission, the capsule will fly on a two orbit test flight to an altitude of 3,600 miles above Earth’s surface, farther than any human spacecraft has gone in 40 years.
It will then fire braking rockets to plunge back to Earth, re-enter the atmosphere at about 20,000 MPH and test numerous spacecrafts systems, the heat shield and all three parachutes for an ocean splashdown.
Meanwhile other Orion EFT-1 components such as the emergency Launch Abort System (LAS) and Service Module are coming together – read my Orion follow-up reports.
Humans have not ventured beyond low Earth orbit since the Apollo Moon landings ended in 1972. Orion will change that.
Learn more about Orion, Antares, SpaceX, Curiosity and NASA robotic and human spaceflight missions at Ken’s upcoming lecture presentations:
April 20/21 : “Curiosity and the Search for Life on Mars – (in 3-D)”. Plus “The Space Shuttle Finale and the Future of NASA – Orion, SpaceX, Antares and more!” NEAF Astronomy Forum, Rockland Community College, Suffern, NY. 3-4 PM Sat & Sunday. Display table all day.
April 28: “Curiosity and the Search for Life on Mars – (in 3-D)”. Plus the Space Shuttle, SpaceX, Antares, Orion and more. Washington Crossing State Park, Titusville, NJ, 130 PM
Orion EFT-1 crew cabin construction ongoing at the Kennedy Space Center which is due to blastoff in September 2014 atop a Delta 4 Heavy rocket. Credit: Ken Kremer
Image caption: Orion deep space crew capsule float passes in front of the White House at the Presidential Inaugural parade on Jan 21, 2013 in Washington, DC. Credit: NASA
NASA’s new Orion deep space crew capsule and sensational Curiosity Mars rover had starring roles at the 2013 Presidential Inaugural Parade held on Monday, Jan 21, 2013 in Washington D.C.
NASA photographers captured stunning photos and video (above and below) as Orion and Curiosity passed in front of the White House and the official reviewing stand – with President Obama & VP Joe Biden and their families and numerous dignitaries smiling and waving.
Beautiful weather shined though out the entire day’s festivities and into the early evening as full size models of Orion and Curiosity made their way thought the capitol streets to participate in the 2013 Inaugural parade.
NASA’s floats prominently placed near the front of the parade and seen on Live TV about 530 PM EDT as well as by about a million spectators on hand.
Image caption: Curiosity Mars rover float passes in front of the White House and reviewing stand at the Presidential Inaugural parade on Jan 21, 2013 in Washington, DC. Credit: NASA
The fantastically successful Curiosity rover is discovering widespread evidence for the ancient flow of liquid water on Mars.
The Orion multi-purpose capsule will take our astronauts back to the Moon and farther into deep space than ever before.
NASA is the ONLY federal agency asked to be in the inaugural parade. Curiosity led the way followed by Orion.
Video of full-size models of the Curiosity Mars rover and Orion, the multi-purpose capsule that will take our astronauts farther into space than ever, as they appeared in the Washington, D.C. parade on Jan. 21.
Accompanying the NASA vehicles were members of the Curiosity team from NASA’s Jet Propulsion Laboratory, and current and former astronauts Alvin Drew, Serena Aunon, Kate Rubins, Mike Massimino, Lee Morin and Kjell Lindgren, as well as Leland Melvin, NASA’s associate administrator for Education, and John Grunsfeld, NASA’s associate administrator for Science.
Be sure to check out NASA’s Flickr stream for many photos from the 2013 Inaugural Day festivities and parade – here and here
Image caption: Orion EFT-1 crew cabin construction ongoing inside the Structural Assembly Jig at the Operations and Checkout Building (O & C) at the Kennedy Space Center (KSC). This is the inaugural space-bound Orion vehicle due to blastoff from Florida in September 2014 atop a Delta 4 Heavy rocket. Credit: Ken Kremer
NASA is thrusting forward and making steady progress toward launch of the first space-bound Orion crew capsule -designed to carry astronauts to deep space. The agency aims for a Florida blastoff of the uncrewed Exploration Flight Test-1 mission (EFT-1) in September 2014 – some 20 months from now – NASA officials told Universe Today.
I recently toured the Orion spacecraft up close during an exclusive follow-up visit to check the work in progress inside the cavernous manufacturing assembly facility in the Operations and Checkout Building (O & C) at the Kennedy Space Center (KSC). Vehicle assemblage is run under the auspices of prime contractor Lockheed Martin Space Systems Corporation.
A lot of hardware built by contractors and subcontractors from all across the U.S. is now arriving at KSC and being integrated with the EFT-1 crew module (CM), said Jules Schneider, Orion Project manager for Lockheed Martin at KSC, during an interview with Universe Today beside the spacecraft at KSC.
“Everyone is very excited to be working on the Orion. We have a lot of work to do. It’s a marathon not a sprint to build and test the vehicle,” Schneider explained to me.
My last inspection of the Orion was at the official KSC unveiling ceremony on 2 July 2012 (see story here). The welded, bare bones olive green colored Orion shell had just arrived at KSC from NASA’s Michoud facility in New Orleans. Since then, Lockheed and United Space Alliance (USA) technicians have made significant progress outfitting the craft.
Workers were busily installing avionics, wiring, instrumentation and electrical components as the crew module was clamped in place inside the Structural Assembly Jig during my follow-up tour. The Jig has multiple degrees of freedom to move the capsule and ease assembly work.
“Since July and to the end of 2012 our primary focus is finishing the structural assembly of the crew module,” said Schneider.
“Simultaneously the service module structural assembly is also ongoing. That includes all the mechanical assembly inside and out on the primary structure and all the secondary structure including the bracketry. We are putting in the windows and gussets, installing the forward bay structure leading to the crew tunnel, and the aft end CM to SM mechanism components. We are also installing secondary structures like mounting brackets for subsystem components like avionics boxes and thruster pods as parts roll in here.”
Image caption: Window and bracket installation on the Orion EFT-1 crew module at KSC. Credit: Ken Kremer
“A major part of what we are doing right now is we are installing a lot of harnessing and test instrumentation including alot of strain gauges, accelerometers, thermocouples and other gauges to give us data, since that’s what this flight is all about – this is a test article for a test flight.
“There is a huge amount of electrical harnesses that have to be hooked up and installed and soldered to the different instruments. There is a lot of unique wiring for ground testing, flight testing and the harnesses that will be installed later along with the plumbing. We are still in a very early stage of assembly and it involves alot of very fine work,” Schneider elaborated. Ground test instrumentation and strain gauges are installed internally and externally to measure stress on the capsule.
Construction of the Orion service module is also moving along well inside the SM Assembly Jig at an adjacent work station. The SM engines will be mass simulators, not functional for the test flight.
Image caption: Orion EFT-1 crew cabin and full scale mural showing Orion Crew Module atop Servivce Module inside the O & C Building at the Kennedy Space Center, Florida. Credit: Ken Kremer
The European Space Agency (ESA) has been assigned the task of building the fully functional SM to be launched in 2017 on NASA’s new SLS rocket on a test flight to the moon and back.
Although Orion’s construction is proceeding apace, there was a significant issue during recent proof pressure testing at the O & C when the vehicle sustained three cracks in the aft bulkhead of the lower half of the Orion pressure vessel.
“The cracks did not penetrate the pressure vessel skin, and the structure was holding pressure after the anomaly occurred,” Brandi Dean, a NASA Public Affairs Officer told me. “The failure occurred at 21.6 psi. Full proof is 23.7 psi.”
“A team composed of Lockheed Martin and NASA engineers have removed the components that sustained the cracks and are developing options for repair work. Portions of the cracked surface were removed and evaluated, letting the team eliminate problems such as material contamination, manufacturing issues and preexisting defects from the fault tree. The cracks are in three adjacent, radial ribs of this integrally machined, aluminum bulkhead,” Dean stated.
Image caption: NASA graphic of 3 cracks discovered during recent proof pressure testing. Credit: NASA
The repairs will be subjected to rigorous testing to confirm their efficacy as part of the previously scheduled EFT-1 test regimen.
A great deal of work is planned over the next few months including a parachute drop test just completed this week and more parachute tests in February 2013. The heat shield skin and its skeleton are being manufactured at a Lockheed facility in Denver, Colorado and shipped to KSC. They are due to be attached in January 2013 using a specialized tool.
“In March 2013, we’ll power up the crew module at Kennedy for the first time,” said Dean.
Orion will soar to space atop a mammoth Delta IV Heavy booster rocket from Launch Complex 37 at Cape Canaveral Air Force Station in Florida. Construction and assembly of the triple barreled Delta IV Heavy is the pacing item upon which the launch date hinges, NASA officials informed me.
Following the forced retirement of NASA’s space shuttles, the United Launch Alliance Delta IV Heavy is now the most powerful booster in the US arsenal and heretofore has been used to launch classified military satellites. Other than a specialized payload fairing built for Orion, the rocket will be virtually identical to the one that boosted a super secret U.S. National Reconnaissance Office (NRO) spy satellite to orbit on June 29, 2012 (see my launch story here).
Orion will fly in an unmanned configuration during the EFT-1 test flight and orbit the Earth two times – reaching an altitude of 3,600 miles which is 15 times farther than the International Space Station’s orbital position. The primary objective is to test the performance of Orion’s heat shield at the high speeds and searing temperatures generated during a return from deep space like those last experienced in the 1970’s by the Apollo moon landing astronauts.
The EFT-1 flight is not the end of the road for this Orion capsule.
“Following the EFT-1 flight, the Orion capsule will be refurbished and reflown for the high altitude abort test, according to the current plan which could change depending on many factors including the budget,” explained Schneider.
“NASA will keep trying to do ‘cool’ stuff”, Bill Gerstenmaier, the NASA Associate Administrator for Human Space Flight, told me.
Stay tuned – Everything regarding human and robotic spaceflight depends on NASA’s precarious budget outlook !
Image caption: Orion EFT-1 crew cabin assemblage inside the Structural Assembly Jig at the Operations and Checkout Building (O & C) at the Kennedy Space Center (KSC); Jules Schneider, Orion Project Manager for Lockheed Martin and Ken Kremer. Credit: Ken Kremer
Orion Test Capsule at Practice for Pad Abort 1 Test. The Orion test capsule is now on a cross country tour from New Mexico to Florida with stops in Oklahoma, Texas and Alabama. Ground teams in White Sands, New Mexico, practice stacking test versions of Orion and its launch abort system. This was being done in advance of Orion’s launch abort system test. Credit: NASA or National Aeronautics and Space Administration
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Here’s your chance for a birds-eye view of an Orion capsule, up-close and personal ! Catch it if you can !
A full scale test version of one of NASA’s Orion spacecraft has embarked on a cross country tour from White Sands, New Mexico, across several states in the southern United States that ultimately lands at the Kennedy Space Center in Florida.
Starting today, Jan. 27, an Orion spacecraft is open for viewing by the public in Texas at Victory Park and the American Airlines Center in Dallas.
Orion fans in Texas
The Coopers from Southlake meet NASA astronaut Nick Patrick by the Orion crew module now on display at the American Airlines Center in Dallas, TX.
The display continues throughout this weekend after a well received visit to Oklahoma at the Science Museum Oklahoma in Oklahoma City.
Roller Derby team visits Orion test capsule now on public display in Texas
The next stop on the cross country journey is the U.S. Space and Rocket Center in Huntsville, Ala on Feb 1-2.
Orion is NASA’s next generation human spaceflight vehicle that will eventually replace the space shuttle and loft astronauts to low Earth orbit and beyond to deep space destinations such as the Moon, Asteroids and Mars. It can also dock at the International Space Station (ISS).
The Orion crew module journey is a wonderful and fun opportunity for individuals and families to see real space exploration hardware with your own eyes and learn all about the goals and plans of the US Space Program and your investment in it as a taxpayer.
Knowledgeable Orion experts will be on hand to speak with visitors in easy to understand ways. This includes astronauts, engineers, program officials and press spokespeople from NASA, Lockheed-Martin (Orion prime contractor) and other companies involved in building the Orion capsule and other components that will rocket the vehicle to orbit.
Veteran NASA Astronauts Nick Patrick and Clay Anderson will be on hand at the Dallas stop. NASA Astronauts Doug Hurley and Jim Dutton will attend the Alabama display.
Hurley was the pilot for the final shuttle mission by Space Shuttle Atlantis for the STS-135 mission to the International Space Station.
Orion fans in Oklahoma. Credit: NASA
The Orion tour also includes colorful and informative display panels and fun kids activities that I’ve personally witnessed on several occasions. In past years the Orion Launch Abort System (LAS) engaged in similar trips.
This Orion test vehicle was used by ground crews preparing for the PA-1 launch abort system flight test that took place in New Mexico in 2010.
The first orbital flight test of an unmanned Orion is scheduled for 2014 atop a Delta 4 Heavy booster..
Orion fans in Dallas, Texas - Mike, Darnell and AkeemOrion Test capsule with test facility workers at White Sands Facility, New Mexico. Credit: NASA
Look here for more information on the Orion stops in Texas and Alabama
American Airlines Center: http://www.americanairlinescenter.com/
U.S. Space and Rocket Center: http://www.ussrc.com/
NASA’s future has suddenly become a hot topic in the GOP Presidential Debates. Orion is at the center of that debate on whether Americans will ever return to the Moon.
This is your opportunity to see history in the making
American astronauts aboard an Orion spacecraft could be launched on a Lunar fly by mission in 2016 atop NASA’s Heavy Lift Launch Vehicle. Credit: Credit: Lockheed Martin
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KENNEDY SPACE CENTER – Despite utilizing just half the work force originally planned and cutting back further on the original test program, Lockheed Martin is now accelerating the Orion Multi-Purpose Crew Vehicle (MPCV) launch schedule and aiming to achieve an Earth orbital flight by 2013 and a human crewed flight as early as 2016. The first Orion crew cabin has been built and construction of the second spacecraft has begun.
What’s more is that a bold “manned mission beyond low Earth orbit and even a lunar fly by is possible in 2016 if NASA’s new heavy lift rocket is developed in time,” says John Karas, vice president of Lockheed Martin’s Human Space Flight programs, in an exclusive interview with Universe Today. A bipartisan majority in Congress recently approved funding for the Heavy lift booster and mandated that the first flight occur in 2016.
“In order to go to the moon, we need NASA’s new heavy lifter,” Karas explained. Orion was designed with the capability to fly human crews to low Earth orbit (LEO) and the International Space Station, as well as beyond to deep space, the Moon, Asteroids, Lagrange Points and Mars.
Lockheed Martin is the prime contractor for Orion under a multi-year contract awarded by NASA in 2006.
First Orion Crew module
Orion crew module during recent installation of back shell panel at Lockheed Martin’s Vertical Test Facility in Denver, Colorado. Credit: NASA
Karas told me that the streamlined test program would involve flying one Orion mission per year – of increasing complexity – from 2013 to 2016. “Lockheed Martin is working with NASA to determine what are the right launch vehicles and the right missions.”
American astronauts could return to the moon in 5 years after a more than 40 year long hiatus.
Orion crew module at Lockheed’s Denver Space Faciilty. First Orion Crew module being outfitted with doors, windows and thermal protection system and more at Lockheed facilities in Denver. Credit: NASA
“Right now we are building a brand new crew cabin for the first Orion mission; OFT-1. But everything depends on the budget.”
“For the inaugural Orion test flight in 2013 NASA is considering a Delta IV Heavy booster rocket,” Karas said. “The Atlas V is not powerful enough to send the whole 50,000 pound spacecraft into orbit. With an Atlas we could only launch an Orion crew module. You would have to have delete the Service Module (SM) and /or other subsystems.”
“Orion would be lofted some 7,000 miles out, and then sent back for Earth reentry to simulate something close to lunar velocity, around 80% or so. So we would definitely be testing the deep space environment. Therefore the test flight would be a lot more involved than just a simple Earth orbital reentry.
“For the first Orion mission, we will put as much capability on it as possible depending on the budget,” Karas amplified. “But it’s unlikely to have solar arrays without a few hundred million more bucks. The capability is money limited.”
“The 2014 flight could be a high altitude abort test or perhaps something else.”
“Then a full up unmanned test flight would follow in 2015,” Karas explained.
“If we have a heavy lifter, the 2016 flight with the first human crew could be a deep space mission or a lunar fly by lasting more than a week.”
Orion crew module boosted by upper stage to the Moon and deep space. Credit: Lockheed Martin
Lockheed has already constructed the initial Orion crew vehicle – known as the first article or Ground Test Article (GTA). The Orion GTA first article was built at NASA’s Michoud Assembly Facility (MAF) in New Orleans, LA where I inspected it after the structural framework was welded into one piece.
Following the installation of mass and volume simulators and a successful series of pressure tests, the first article was then shipped in February this year to the company’s new state-of-the-art Space Operation Simulation Center (SOSC) located in Denver, Colorado.
“At Denver, we are going to finish the assembly of the first article by July of this year so it looks like a spacecraft – adding the doors, windows, thermal tiles and more,” Karas said. “Then it undergoes rigorous acoustics tests until September – known as Shake and Bake – to simulate all aspects of the harsh environment of deep space.”
The next step after that was to send it to NASA Langley for intensive water drop landing tests. But that plan may well change Karas told me.
“The first article – or GTA – is flight worthy. So we don’t want to break the spacecraft during the water landing tests. In the newly revised plan it may be used on the 2nd Orion flight in 2014 instead of reserving it for ground tests only. It would fly with a service module, but not solar panels. The first article could even be the first flight vehicle if the program funding is insufficient.”
Orion prototype crew cabin - GTA
Orion cabin view with astronaut crew hatch and window openings at NASA Michoud Assembly Facility, New Orleans, LA is now undergoing testing and integration at Lockheed’s new state-of-the-art Space Operation Simulation Center (SOSC) in Denver, Colorado. Credit: Ken Kremer
“We have only half the budget for Orion that was planned earlier by NASA,” Karas stated.
“1500 less people are working on Orion since 1 year ago from the start to the end of 2010 – and that number includes all the subcontractors. We had to lay off a lot of people, including some folks we intended to hire.”
“MAF is now focused on building the composite structures of the first Service Module with about 200 people. That’s about half of what should have been about 400 folks. The earlier work at Michoud (MAF) focused on the metallic structures of the cabin for the first article,” said Karas.
To a large degree, launching astronauts to deep space is more a matter of sheer political will power then solving technical issues. And it all comes down to the bucks.
If NASA’s Heavy lifter is not available an alternative scenario with other expendable rockets would have to be developed to achieve the escape velocity required to send a crew of astronauts to the Moon.
Lockheed Martin has independently proposed a stepping stone approach that would send astronauts in Orion spacecraft to challenging deep space targets such as the Moon, and elsewhere such as Asteroids, Lagrange points and Mars that have never been done before and which I’ll feature in upcoming articles.
“Exploration missions that are affordable and sustainable will inevitably lead to technological innovation, to scientific discovery, and to public inspiration and spark an interest in STEM careers that can help the United States counter the overwhelming numerical disadvantage in college graduates it faces in these disciplines in developing third-world nations,’ says Karas.
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