Orion takes shape for 2014 Test Flight

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

KENNEDY SPACE CENTER, FL – NASA is picking up the pace of assembly operations for the Orion capsule, America’s next crew vehicle destined to carry US astronauts to Asteroids, the Moon, Mars and Beyond.

Just over a year from now in September 2014, NASA will launch Orion on its first test flight, an unpiloted mission dubbed EFT-1.

At NASA’s Kennedy Space Center in Florida, expert work crews are already hard at work building a myriad of Orion’s key components, insuring the spacecraft takes shape for an on time liftoff.

Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) 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
Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) 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
Universe Today is reporting on NASA’s progress and I took an exclusive behind the scenes tour inside KSC facilities to check on Orion’s progress.

In 2014 Orion will blast off to Earth orbit atop a mammoth Delta IV Heavy booster, the most powerful booster in America’s rocket fleet following the retirement of NASA’s Space Shuttle orbiters in 2011.

On later flights Orion will blast off on the gargantuan Space Launch System (SLS), the world’s most powerful rocket which is simultaneously under development by NASA.

At the very top of the Orion launch stack sits the Launch Abort System (LAS) – a critically important component to ensure crew safety, bolted above the crew module.

In case of an emergency situation, the LAS is designed to ignite within milliseconds to rapidly propel the astronauts inside the crew module away from the rocket and save the astronauts lives.

The LAS is one of the five primary components of the flight test vehicle for the EFT-1 mission.

Astronaut hatch swung open on Orion capsule mock up joined to base of Launch Abort System (LAS) emergency escape tower.   Credit: Ken Kremer/kenkremer.com
Astronaut hatch swung open on Orion capsule mock up joined to base of Launch Abort System (LAS) emergency escape tower. Credit: Ken Kremer/kenkremer.com

Prior to any launch from the Kennedy Space Center, all the rocket components are painstakingly attached piece by piece.

Final assembly for EFT-1 takes place inside the iconic Vehicle Assembly Building (VAB).

To get a head start on assembly with the launch date relentlessly approaching, technicians have been practicing lifting and stacking techniques for several months inside the VAB transfer aisle using the 6 ton LAS pathfinder replica and mock ups of the Orion crew and service modules.

This 175 ton hook and crane system used to maneuver the Orion crew capsule, Service Module and Launch Abort System (LAS) components inside the Vehicle Assembly Building the Kennedy Space Center (KSC) in Florida. Credit: Ken Kremer/kenkremer.com
This 175 ton hook and crane system used to maneuver the Orion crew capsule, Service Module and Launch Abort System (LAS) components inside the Vehicle Assembly Building the Kennedy Space Center (KSC) in Florida. Credit: Ken Kremer/kenkremer.com

Conducting the practice sessions now with high fidelity replicas serves multiple purposes, including anticipating and solving problems now before the real equipment arrives, as well as to keep the teams proficient between the years long launch gap between the finale of the Space Shuttle program and the start up of the Orion/SLS deep space exploration program.

Delicate maneuvers like lifting, rolling, rotating, stacking, gimballing and more of heavy components requiring precision placements is very demanding and takes extensive practice to master.

There is no margin for error. Human lives hang in the balance.

Technicians at work practicing de-stacking operations with full size mockups of the Orion capsule and Launch Abort System components inside the Vehicle Assembly Building at the Kennedy Space Center in Florida. Credit: /Jim Grossmann
Technicians at work practicing de-stacking operations with full size mockups of the Orion capsule and Launch Abort System components inside the Vehicle Assembly Building at the Kennedy Space Center in Florida. Credit: NASA/Jim Grossmann

The same dedicated crews that assembled NASA’s Space Shuttles inside the VAB for 3 decades are assembling Orion. And they are using the same equipment.

“The breakover, taking the LAS from horizontal to vertical, is not as easy as it sometimes seems, but the VAB guys are exceptional, they are really good at what they do so they really didn’t have a problem,” says Douglas Lenhardt, who is overseeing the Orion mock-up and operations planning for the Ground Systems Development and Operations program, or GSDO.

Simulations with computer models are extremely helpful, but real life situations can be another matter.

“Real-life, things don’t always work perfectly and that’s why it really does help having a physical model,” says Lenhardt.

One day our astronauts will climb through an Orion hatch like this for America’s ‘Return to the Moon’ - following in the eternal footsteps of Apollo 11’s Neil Armstrong and Buzz Aldrin.  Credit: Ken Kremer/kenkremer.com
One day our astronauts will climb through an Orion hatch like this for America’s ‘Return to the Moon’ – following in the eternal footsteps of Apollo 11’s Neil Armstrong and Buzz Aldrin.
Credit: Ken Kremer/kenkremer.com

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.

Ken Kremer

Orion soars skyward in 2014 for the first time. Credit: Ken Kremer/kenkremer.com
Orion soars skyward in 2014 for the first time.
Credit: Ken Kremer/kenkremer.com

Orion Capsule Accelerating to 2014 Launch and Eventual Asteroid Exploration

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
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
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.
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.

Ken Kremer

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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
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

Beautiful Astrophoto: Zoom Into Orion

A poster with a progression of images from Cape Espichel, Sesimbra in Spain. Left is a wide field starscape, center is Orion's deep sky objects and right is a closeup of M42. Credit and copyright: Miguel Claro.

Here’s an awesome sequence of images from skyscape photographer Miguel Claro. These images were captured from Cape Espichel, Sesimbra, Portugal, about 40 km away from Lisbon. This triple sequence poster contains a beautiful widefield view of the well-known winter constellations visible from the northern hemisphere; then a zoom in to focus on Orion; then Claro zooms in even more to find the Great Orion Nebula M42 and M43.

Claro took a single shot for each image with a DSLR camera, using between 10, 35 and 300 mm. “To do this work I´ve used the incredible Vixen Polarie mounting travel, to avoid the Earth rotation, and a Canon 60Da, a camera sensitive to the infrared/H-alpha wavelengths,” Claro said.

Below is an annotated version of the different objects in the image:

An annotated poster with a progression of images from Cape Espichel, Sesimbra in Portugal. Left is a wide field starscape, center is Orion's deep sky objects and right is a closeup of M42. Credit and copyright: Miguel Claro.
An annotated poster with a progression of images from Cape Espichel, Sesimbra in Portugal. Left is a wide field starscape, center is Orion’s deep sky objects and right is a closeup of M42. Credit and copyright: Miguel Claro.

You can see these images and more at Claro’s website, http://miguelclaro.com/

Want to get your astrophoto featured on Universe Today? Join our Flickr group or send us your images by email (this means you’re giving us permission to post them). Please explain what’s in the picture, when you took it, the equipment you used, etc.

NASA: Reaches for New Heights – Greatest Hits Video

Video Caption: At NASA, we’ve been a little busy: landing on Mars, developing new human spacecraft, going to the space station, working with commercial partners, observing the Earth and the Sun, exploring our solar system and understanding our universe. And that’s not even everything.Credit: NASA

Check out this cool action packed video titled “NASA: Reaching for New Heights” – to see NASA’s ‘Greatest Hits’ from the past year

The 4 minute film is a compilation of NASA’s gamut of Robotic Science and Human Spaceflight achievements to explore and understand Planet Earth here at home and the heavens above- ranging from our Solar System and beyond to the Galaxy and the vast expanse of the Universe.

Image caption: Planets and Moons in perspective. Credit: NASA

The missions and programs featured include inspiringly beautiful imagery from : Curiosity, Landsat, Aquarius, GRACE, NuSTAR, GRAIL, Dawn at Asteroid Vesta, SDO, X-48C Amelia, Orion, SLS, Apollo, SpaceX, Sierra Nevada Dream Chaser, Boeing CST-100, Commercial Crew, Hurricane Sandy from the ISS, Robonaut and more !

And even more space exploration thrills are coming in 2013 !

Ken Kremer

IMG_3760a_SpaceX launch 22 May 2012

Image caption: SpaceX Falcon 9 rocket blasts off on May 22, 2012 with Dragon cargo capsule from Space Launch Complex-40 at Cape Canaveral Air Force Station, Fla., on the first commercial mission to the International Space Station. The next launch is set for March 1, 2013. Credit: Ken Kremer

NASA Stars at 2013 Presidential Inaugural Parade with Orion and Curiosity – Photos and Video

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.

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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

See my preview story – here

Ken Kremer

NASA’s Curiosity and Orion Shine at Presidential Inaugural Parade

Video caption: Preview of Mars Curiosity Parade Float. Jim Green, Director of the Science Mission Directorate Planetary Systems Division at NASA Headquarters, describes the replica of the Mars Curiosity Rover on the second NASA float in Monday’s (Jan 21, 2013) presidential inaugural parade. Parade photos below

Full scale models of NASA’s Curiosity Mars rover and the Orion crew capsule are participating in the 2013 Presidential Inaugural Parade on Monday, Jan 21, 2013, in Washington, DC – representing NASA’s robotic and human spaceflight endeavors.

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 space than ever.

NASA is the ONLY federal agency asked to be in the inaugural parade and now Curiosity is leading the NASA group with Orion after Curiosity.

Update 530 PM EDT – NASA’s 2 floats just passed by a cheering and waving President Obama & VP Biden at the reviewing stand in front of the White House – prominently near the front of the parade. See float photos from the parade below

Walking alongside both floats are members of the Curiosity team from NASA’s Jet Propulsion Laboratory – including ‘Mohawk Guy’ – and several current and former astronauts.

The participating astronauts are 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.

The marching team for Curiosity includes Richard Cook-project manager (from JPL), Bobak Ferdowsi (otherwise known as ‘Mohawk Guy’)-flight director (from JPL), Dave Lavery – program executive (from NASA Headquarters) , Michael Meyer – program Scientist (from NASA Headquarters), Jennifer Trosper-mission manager (from JPL) and Ashwin Vasavada, Deputy Project Scientist (from JPL)

Image caption: Orion crew capsule float with NASA astronauts at the Presidential Inaugural parade on Jan 21, 2013 in Washington, DC. Credit: NASA

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Image caption: Curiosity float with team members at the Presidential Inaugural parade on Jan 21, 2013 in Washington, DC. Credit: NASA

Be sure to check out NASA’s Flickr stream for many photos from the 2013 Inaugural Day festivities and parade – here and here

Here’s another video about the Curiosity float:

Ken Kremer

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Image caption: Orion crew capsule arrives in Washington, DC, for Presidential Inaugural parade on Jan 21, 2013. Credit: NASA

New Look and New Animation for Orion’s 2017 Flight to the Moon and Back

The Orion spacecraft has gotten a new look for its first launch atop the inaugural flight of NASA’s Space Launch System (SLS) booster on the Exploration Mission-1 flight around the Moon in 2017 as seen in this new animation.

The vehicles service module will be built by the European Space Agency (ESA), as a result of a new bilateral agreement between NASA and ESA. Orion is designed to carry humans back to the Moon and to deep space destinations like Asteroids and Mars.

The service module will fuel and propel the capsule on its uncrewed journey to the Moon and back on EM-1 in 2017.

Read my follow-up report for details about the new NASA/ESA agreement. See my earlier story here, about preparations for the first Orion launch in September 2014 on the upcoming Exploration Flight Test-1 in 2014 atop a Delta IV Heavy. An unmanned Orion will fly on a two orbit test flight to an altitude of 3,600 miles above Earth’s surface, farther than a human spacecraft has gone in 40 years, and then plunge back to Earth to test the spacecrafts systems and heat shield.

NASA is also simultaneously fostering the development of commercial ‘space taxis’ to fly astronauts to the International Space Station (ISS) as part of a dual track approach to restore America’s human space launch capability. The 1st commercial crew vehicle might fly as early as 2015 – details here.

Ken Kremer

Image caption: 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

Orion assemblage on track for 2014 Launch

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 !

Ken Kremer

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

‘NASA Johnson Style’ Parodies ‘Gangnam Style’ Music Video

Check this out and get in the groove to enjoy some really cool fun from NASA

NASA interns and NASA astronauts have joined forces to create a very humorous and entertaining music video parody of the “Gangnam Style” mega hit by international pop sensation PSY – It’s called “NASA Johnson Style” and its New!

A team of interns from NASA’s Johnson Space Center (pictured below) in Houston created original lyrics, convinced several initially incredulous astronauts to dance along and shot the video at several NASA centers. Then they integrated the whole kit and kaboodle with the “Gangnam Style” instrumental track. Scotty would be proud of the intricate engineering demanded to pull this off – but where are the tribbles !

Image caption: Mike Massimino (center) poses with the intern video team after filming at JSC. Photo credit: Nicole Cloutier

The video features a fun loving crew of NASA astronauts including Mike Massimino, who deftly repaired the Hubble Space Telescope twice among other things, Clayton Anderson and Tracy Caldwell Dyson who lived and worked for many months aboard the International Space Station, and Mike Coats, a Shuttle commander and the retiring Director of the Johnson Space Center.

The video also features actual footage from the International Space Station , Apollo Moonwalks, Curiosity on Mars, Dawn at Vesta, Houston Mission control, the SLS and Orion Crew vehicle as well as real research labs and scientists here on Earth. So it’s fun and meant to be educational as well.

“Gangnam Style” by the Korean singing star PSY is the most popular YouTube music ever and is enjoyed by millions more every day since it was released last summer. It has spawned numerous other parodies.

And in case you missed last summer’s mega hit parody straight from the Red Planet – click on this: “We’re NASA and We Know It (Mars Curiosity)” – Note: this is NOT a NASA production

Now, turn up the volume and enjoy some light hearted cheer in this Holiday season.

Ken Kremer

Orion Revisited: Astronomers Find New Star Cluster in Front of the Orion Nebula

The well-known star-forming region of the Orion Nebula.  Credit: Canada-France-Hawaii Telescope / Coelum (J.-C. Cuillandre & G. Anselmi)

Precise distances are difficult to gauge in space, especially within the relatively local regions of the Galaxy. Stars which appear close together in the night sky may actually be separated by many hundreds or thousands of light-years, and since there’s only a limited amount of space here on Earth with which to determine distances using parallax, astronomers have to come up with other ways to figure out how far objects are, and what exactly is in front of or “behind” what.

Recently, astronomers using the 340-megapixel MegaCam on the Canada-France-Hawaii Telescope (CFHT) observed the star-forming region of the famous Orion nebula — located only about 1,500 light-years away — and determined that two massive groupings of the nebula’s stars are actually located in front of the cluster as completely separate structures… a finding that may ultimately force astronomers to rethink how the many benchmark stars located there had formed.

Although the Orion nebula is easily visible with the naked eye (as the hazy center “star” in Orion’s three-star sword, hanging perpendicular below his belt) its true nebulous nature wasn’t identified until 1610. As a vast and active star-forming region of bright dust and gas located a mere 1,500 light-years distant, the various stars within the Orion Nebula Cluster (ONC) has given astronomers invaluable benchmarks for research on many aspects of star formation.

[Read more: Astrophoto – Orion’s Bloody Massacre]

Now, CFHT observations of the Orion nebula conducted by Dr. Hervé Bouy of the European Space Astronomy Centre (ESAC) and Centre for Astrobiology (CSIC) and Dr. João Alves of the Institut für Astronomie (University of Vienna) have shown that a massive cluster of stars known as NGC 1980 is actually in front of the nebula, and is an older group of approximately 2,000 stars that is separate from the stars found within the ONC… as well as more massive than once thought.

“It is hard to see how these new observations fit into any existing theoretical model of cluster formation, and that is exciting because it suggests we might be missing something fundamental.”

– Dr. João Alves, Institut für Astronomie, University of Vienna

In addition their observations with CFHT — which were combined with previous observations with ESA’s Herschel and XMM-Newton and NASA’s Spitzer and WISE — have led to the discovery of another smaller cluster, L1641W.

According to the team’s paper, “We find that there is a rich stellar population in front of the Orion A cloud, from B-stars to M-stars, with a distinct 1) spatial distribution; 2) luminosity function; and 3) velocity dispersion from the reddened population inside the Orion A cloud. The spatial distribution of this population peaks strongly around NGC 1980 (iota Ori) and is, in all likelihood, the extended stellar content of this poorly studied cluster.”

The findings show that what has been known as Orion Nebula Cluster is actually a combination of older and newer groups of stars, possibly calling for a “revision of most of the observables in the benchmark ONC region (e.g., ages, age spread, cluster size, mass function, disk frequency, etc.)”

[Read more: Astronomers See Stars Changing Right Before Their Eyes in Orion Nebula]

“We must untangle these two mixed populations, star by star, if we are to understand the region, and star formation in clusters, and even the early stages of planet formation,” according to co-author Dr. Hervé Bouy.

The team’s article “Orion Revisited” was published in the November 2012 Astronomy & Astrophysics journal. Read the CFHT press release here.

The Canada-France-Hawaii Telescope’s Mauna Kea summit dome in September 2009. Credit: CFHT/Jean-Charles Cuillandre

Inset image: Orion nebula seen in optical – where the molecular cloud is invisible – and infrared, which shows the cloud. Any star detected in the optical in the line of sight over the region highlighted in the right panel must therefore be located in the foreground of the molecular cloud. Credit: J. Alves & H. Bouy.