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NASA NTRS2005

High-Temperature Structures, Adhesives, and Advanced Thermal Protection Materials for Next-Generation Aeroshell Design

The next generation of planetary exploration vehicles will rely heavily on robust aero-assist technologies, especially those that include aerocapture. This paper provides an overview of an ongoing development program, led by NASA Langley Research Center (LaRC) and aimed at introducing high-temperature structures, adhesives, and advanced thermal protection system (TPS) materials into the aeroshell design process. The purpose of this work is to demonstrate TPS materials that can withstand the higher heating rates of NASA's next generation planetary missions, and to validate high-temperature structures and adhesives that can reduce required TPS thickness and total aeroshell mass, thus allowing for larger science payloads. The effort described consists of parallel work in several advanced aeroshell technology areas. The areas of work include high-temperature adhesives, high-temperature composite materials, advanced ablator (TPS) materials, sub-scale demonstration test articles, and aeroshell modeling and analysis. The status of screening test results for a broad selection of available higher-temperature adhesives is presented. It appears that at least one (and perhaps a few) adhesives have working temperatures ranging from 315-400 C (600-750 F), and are suitable for TPS-to-structure bondline temperatures that are significantly above the traditional allowable of 250 C (482 F). The status of mechanical testing of advanced high-temperature composite materials is also summarized. To date, these tests indicate the potential for good material performance at temperatures of at least 600 F. Application of these materials and adhesives to aeroshell systems that incorporate advanced TPS materials may reduce aeroshell TPS mass by 15% - 30%. A brief outline is given of work scheduled for completion in 2006 that will include fabrication and testing of large panels and subscale aeroshell test articles at the Solar-Tower Test Facility located at Kirtland AFB and operated by Sandia National Laboratories. These tests are designed to validate aeroshell manufacturability using advanced material systems, and to demonstrate the maintenance of bondline integrity at realistically high temperatures and heating rates. Finally, a status is given of ongoing aeroshell modeling and analysis efforts which will be used to correlate with experimental testing, and to provide a reliable means of extrapolating to performance under actual flight conditions. The modeling and analysis effort includes a parallel series of experimental tests to determine TSP thermal expansion and other mechanical properties which are required for input to the analysis models.

Collins, Timothy J.↗
NASA NTRS2006

Development of Virtual Airspace Simulation Technology - Real-Time (VAST-RT) Capability 2 and Experimental Plans

The Virtual Airspace Simulation Technology - Real-Time (VAST-RT) Project, an element cf NASA's Virtual Airspace Modeling and Simulation (VAMS) Project, has been developing a distributed simulation capability that supports an extensible and expandable real-time, human-in-the-loop airspace simulation environment. The VAST-RT system architecture is based on DoD High Level Architecture (HLA) and the VAST-RT HLA Toolbox, a common interface implementation that incorporates a number of novel design features. The scope of the initial VAST-RT integration activity (Capability 1) included the high-fidelity human-in-the-loop simulation facilities located at NASA/Ames Research Center and medium fidelity pseudo-piloted target generators, such as the Airspace Traffic Generator (ATG) being developed as part of VAST-RT, as well as other real-time tools. This capability has been demonstrated in a gate-to-gate simulation. VAST-RT's (Capability 2A) has been recently completed, and this paper will discuss the improved integration of the real-time assets into VAST-RT, including the development of tools to integrate data collected across the simulation environment into a single data set for the researcher. Current plans for the completion of the VAST-RT distributed simulation environment (Capability 2B) and its use to evaluate future airspace capacity enhancing concepts being developed by VAMS will be discussed. Additionally, the simulation environment's application to other airspace and airport research projects is addressed.

Lehmer, R.↗
NASA NTRS2006

Overview of the Solar-B Mission

The Solar-B mission is a collaboration between the Japan Aerospace Exploration Agency, Institute of Space and Astronautical Science, the National Aeronautics and Space Administration (NASA) and the Particle Physics and Astronomy Research Council (PPARC) of the United Kingdom and the European Space Agency. The principal scientific goals of the mission are to understand the processes of magnetic field generation, transport and ultimate dissipation of solar magnetic fields and how the release of magnetic energy is responsible for the heating and structuring of the chromosphere and corona. The scientific payload consists of three instruments: the Solar Optical Telescope that consists of the Optical Telescope Assembly and the Focal Plane Package (FPP), the X-ray Telescope and the EUV Imaging Spectrometer Each instrument is a result of the combined talents of all the members of the international team and their design and performance is described in separate papers in this session. The instruments are designed to work together as an 'observatory' simultaneously studying the target, at which the spacecraft is pointed, at different levels in the atmosphere. The spacecraft is scheduled for launch in September 2006 from the Uchinoura Space Center into a 600 km circular, sun-synchronous, polar orbit with a nominal elevation of 97.9 degrees. The orbit provides at least two morning and two evening contacts in Japan. Morning contacts are used for recovering quick look science data and the evening contacts for uploading commands. In addition ESA will provide 15 contacts per day from the Norwegian high latitude (78deg 14' N) ground station at Svalbard. The data downloads are transmitted to the ISAS Sirius database. They will be reformatted into FITS files and archived as Level 0 data on the ISAS DARTS system and made available to the scientific community. Scientific operations will be conducted from the IS AS facility located in Sagamihara, Japan. They are separated into planning, implementation and archiving. The planning process involves monthly, weekly and daily planning meetings. All scientific data will be made available after the first six month approximately one week after its collection.

Davis, John M.↗
NASA NTRS2002

Ka-band and X-band observations of the solar corona acquired during the Cassini 2001 superior conjunction

Simultaneous dual-frequency Ka-band (32 GHz) and X-band (8.4 GHz) carrier signal data have been acquired during the superior conjunction of the Cassini spacecraft June 2001, using the NASA Deep Space Network's facilities located in Goldstone, California. The solar elongation angle of the observations varied from -4.1 degrees (-16 solar radii) to -0.6 degrees (-2.3 solar radii). The observed coronal and solar effects on the signals include spectral broadening, amplitude scintillation, phase scintillation, and increased noise. The measurements were generally consistent with existing solar models, except during solar transient events when the signatures of the measurements were observed to increase significantly above the quiet background levels. This is the second solar conjunction of Cassini for which simultaneous X/Ka data were acquired. Both solar conjunctions, conducted in May 2000 and June 2001, occurred near the peak of the current 11 year solar cycle.

propagation scintillation spectral broadening↗
NASA NTRS2008

Understanding Ice Supersaturation, Particle Growth, and Number Concentration in Cirrus Clouds

Many factors control the ice supersaturation and microphysical properties in cirrus clouds. We explore the effects of dynamic forcing, ice nucleation mechanisms, and ice crystal growth rate on the evolution and distribution of water vapor and cloud properties in nighttime cirrus clouds using a one-dimensional cloud model with bin microphysics and remote sensing measurements obtained at the Department of Energy's Atmospheric Radiation Measurement (ARM) Climate Research Facility located near Lamont, OK. We forced the model using both large-scale vertical ascent and, for the first time, mean mesoscale velocity derived from radar Doppler velocity measurements. Both heterogeneous and homogeneous nucleation processes are explored, where a classical theory heterogeneous scheme is compared with empirical representations. We evaluated model simulations by examining both bulk cloud properties and distributions of measured radar reflectivity, lidar extinction, and water vapor profiles, as well as retrieved cloud microphysical properties. Our results suggest that mesoscale variability is the primary mechanism needed to reproduce observed quantities. Model sensitivity to the ice growth rate is also investigated. The most realistic simulations as compared with observations are forced using mesoscale waves, include fast ice crystal growth, and initiate ice by either homogeneous or heterogeneous nucleation. Simulated ice crystal number concentrations (tens to hundreds particles per liter) are typically two orders of magnitude smaller than previously published results based on aircraft measurements in cirrus clouds, although higher concentrations are possible in isolated pockets within the nucleation zone.

Comstock, Jennifer M.↗
NASA NTRS2011

Capability Extension to the Turbine Off-Design Computer Program AXOD With Applications to the Highly Loaded Fan-Drive Turbines

The axial flow turbine off-design computer program AXOD has been upgraded to include the outlet guide vane (OGV) into its acceptable turbine configurations. The mathematical bases and the techniques used for the code implementation are described and discussed in lengths in this paper. This extended capability is verified and validated with two cases of highly loaded fan-drive turbines, designed and tested in the V/STOL Program of NASA. The first case is a 4 1/2-stage turbine with an average stage loading factor of 4.66, designed by Pratt & Whitney Aircraft. The second case is a 3 1/2-stage turbine with an average loading factor of 4.0, designed in-house by the NASA Lewis Research Center (now the NASA Glenn Research Center). Both cases were experimentally tested in the turbine facility located at the Glenn Research Center. The processes conducted in these studies are described in detail in this paper, and the results in comparison with the experimental data are presented and discussed. The comparisons between the AXOD results and the experimental data are in excellent agreement.

Chen, Shu-cheng S.↗
NASA NTRS2012

Common Data Acquisition Systems (DAS) Software Development for Rocket Propulsion Test (RPT) Test Facilities

The advent of the commercial space launch industry and NASA's more recent resumption of operation of Stennis Space Center's large test facilities after thirty years of contractor control resulted in a need for a non-proprietary data acquisition systems (DAS) software to support government and commercial testing. The software is designed for modularity and adaptability to minimize the software development effort for current and future data systems. An additional benefit of the software's architecture is its ability to easily migrate to other testing facilities thus providing future commonality across Stennis. Adapting the software to other Rocket Propulsion Test (RPT) Centers such as MSFC, White Sands, and Plumbrook Station would provide additional commonality and help reduce testing costs for NASA. Ultimately, the software provides the government with unlimited rights and guarantees privacy of data to commercial entities. The project engaged all RPT Centers and NASA's Independent Verification & Validation facility to enhance product quality. The design consists of a translation layer which provides the transparency of the software application layers to underlying hardware regardless of test facility location and a flexible and easily accessible database. This presentation addresses system technical design, issues encountered, and the status of Stennis development and deployment.

Hebert, Phillip W., Sr.↗
NASA NTRS2012

Design and Analysis of an Isokinetic Sampling Probe for Submicron Particle Measurements at High Altitude

An isokinetic dilution probe has been designed with the aid of computational fluid dynamics to sample sub-micron particles emitted from aviation combustion sources. The intended operational range includes standard day atmospheric conditions up to 40,000-ft. With dry nitrogen as the diluent, the probe is intended to minimize losses from particle microphysics and transport while rapidly quenching chemical kinetics. Initial results indicate that the Mach number ratio of the aerosol sample and dilution streams in the mixing region is an important factor for successful operation. Flow rate through the probe tip was found to be highly sensitive to the static pressure at the probe exit. Particle losses through the system were estimated to be on the order of 50% with minimal change in the overall particle size distribution apparent. Following design refinement, experimental testing and validation will be conducted in the Particle Aerosol Laboratory, a research facility located at the NASA Glenn Research Center to study the evolution of aviation emissions at lower stratospheric conditions. Particle size distributions and number densities from various combustion sources will be used to better understand particle-phase microphysics, plume chemistry, evolution to cirrus, and environmental impacts of aviation.

Heath, Christopher M.↗
NASA NTRS2012

Fluorescence-Doped Particles for Simultaneous Temperature and Velocity Imaging

Polystyrene latex microspheres (PSLs) have been used for particle image velocimetry (PIV) and laser Doppler velocimetry (LDV) measurements for several decades. With advances in laser technologies, instrumentation, and data processing, the capability to collect more information about fluid flow beyond velocity is possible using new seed materials. To provide additional measurement capability, PSLs were synthesized with temperature-sensitive fluorescent dyes incorporated within the particle. These multifunctional PSLs would have the greatest impact if they could be used in large scale facilities with minimal modification to the facilities or the existing instrumentation. Consequently, several potential dyes were identified that were amenable to existing laser systems currently utilized in wind tunnels at NASA Langley Research Center as well as other wind and fluid (water) tunnels. PSLs incorporated with Rhodamine B, dichlorofluorescein (DCF, also known as fluorescein 548 or fluorescein 27) and other dyes were synthesized and characterized for morphology and spectral properties. The resulting particles were demonstrated to exhibit fluorescent emission, which would enable determination of both fluid velocity and temperature. They also would allow near-wall velocity measurements whereas laser scatter from surfaces currently prevents near-wall measurements using undoped seed materials. Preliminary results in a wind tunnel facility located at Virginia Polytechnic Institute and State University (Virginia Tech) have verified fluorescent signal detection and temperature sensitivity of fluorophore-doped PSLs.

Danehy, Paul M.↗
NASA NTRS2012

Common Data Acquisition Systems (DAS) Software Development for Rocket Propulsion Test (RPT) Test Facilities - A General Overview

The advent of the commercial space launch industry and NASA's more recent resumption of operation of Stennis Space Center's large test facilities after thirty years of contractor control resulted in a need for a non-proprietary data acquisition system (DAS) software to support government and commercial testing. The software is designed for modularity and adaptability to minimize the software development effort for current and future data systems. An additional benefit of the software's architecture is its ability to easily migrate to other testing facilities thus providing future commonality across Stennis. Adapting the software to other Rocket Propulsion Test (RPT) Centers such as MSFC, White Sands, and Plumbrook Station would provide additional commonality and help reduce testing costs for NASA. Ultimately, the software provides the government with unlimited rights and guarantees privacy of data to commercial entities. The project engaged all RPT Centers and NASA's Independent Verification & Validation facility to enhance product quality. The design consists of a translation layer which provides the transparency of the software application layers to underlying hardware regardless of test facility location and a flexible and easily accessible database. This presentation addresses system technical design, issues encountered, and the status of Stennis' development and deployment.

Hebert, Phillip W., Sr.↗
NASA NTRS2014

The Effects of Long Duration Bed Rest on Functional Mobility and Balance: Relationship to Resting State Motor Cortex Connectivity

NASA offers researchers from a variety of backgrounds the opportunity to study bed rest as an experimental analog for space flight. Extended exposure to a head-down tilt position during long duration bed rest can resemble many of the effects of a low-gravity environment such as reduced sensory inputs, body unloading and increased cephalic fluid distribution. The aim of our study is to a) identify changes in brain function that occur with prolonged bed rest and characterize their recovery time course; b) assess whether and how these changes impact behavioral and neurocognitive performance. Thus far, we completed data collection from six participants that include task based and resting state fMRI. The data have been acquired through the bed rest facility located at the University of Texas Medical Branch (Galveston, TX). Subjects remained in bed with their heads tilted down 6 degrees below their feet for 70 consecutive days. Behavioral measures and neuroimaging assessments were obtained at seven time points: a) 7 and 12 days before bed rest; b) 7, 30, and 65 days during bed rest; and c) 7 and 12 days after bed rest. Functional connectivity magnetic resonance imaging (FcMRI) analysis was performed to assess the connectivity of motor cortex in and out of bed rest. We found a decrease in motor cortex connectivity with vestibular cortex and the cerebellum from pre bed rest to in bed rest. We also used a battery of behavioral measures including the functional mobility test and computerized dynamic posturography collected before and after bed rest. We will report the preliminary results of analyses relating brain and behavior changes. Furthermore, we will also report the preliminary results of a spatial working memory task and vestibular stimulation during in and out of bed rest.

Erdeniz, B.↗
NASA NTRS2014

Ice Particle Impacts on a Moving Wedge

This work presents the results of an experimental study of ice particle impacts on a moving wedge. The experiment was conducted in the Adverse Environment Rotor Test Stand (AERTS) facility located at Penn State University. The wedge was placed at the tip of a rotating blade. Ice particles shot from a pressure gun intercepted the moving wedge and impacted it at a location along its circular path. The upward velocity of the ice particles varied from 7 to 12 meters per second. Wedge velocities were varied from 0 to 120 meters per second. Wedge angles tested were 0, 30, 45, and 60. High speed imaging combined with backlighting captured the impact allowing observation of the effect of velocity and wedge angle on the impact and the post-impact fragment behavior. It was found that the pressure gun and the rotating wedge could be synchronized to consistently obtain ice particle impacts on the target wedge. It was observed that the number of fragments increase with the normal component of the impact velocity. Particle fragments ejected immediately after impact showed velocities higher than the impact velocity. The results followed the major qualitative features observed by other researchers for hailstone impacts, even though the reduced scale size of the particles used in the present experiment as compared to hailstones was 4:1.

Impacts↗
NASA NTRS2014

Ice Particle Impacts on a Moving Wedge

This work presents the results of an experimental study of ice particle impacts on a moving wedge. The experiment was conducted in the Adverse Environment Rotor Test Stand (AERTS) facility located at Penn State University. The wedge was placed at the tip of a rotating blade. Ice particles shot from a pressure gun intercepted the moving wedge and impacted it at a location along its circular path. The upward velocity of the ice particles varied from 7 to 12 meters per second. Wedge velocities were varied from 0 to 120 meters per second. Wedge angles tested were 0 deg, 30 deg, 45 deg, and 60 deg. High speed imaging combined with backlighting captured the impact allowing observation of the effect of velocity and wedge angle on the impact and the post-impact fragment behavior. It was found that the pressure gun and the rotating wedge could be synchronized to consistently obtain ice particle impacts on the target wedge. It was observed that the number of fragments increase with the normal component of the impact velocity. Particle fragments ejected immediately after impact showed velocities higher than the impact velocity. The results followed the major qualitative features observed by other researchers for hailstone impacts, even though the reduced scale size of the particles used in the present experiment as compared to hailstones was 4:1.

Roughness↗
NASA NTRS2015

The Effects of Long Duration Bed Rest as a Spaceflight Analogue on Resting State Sensorimotor Network Functional Connectivity and Neurocognitive Performance

Long duration spaceflight has been associated with detrimental alterations in human sensorimotor systems and neurocognitive performance. Prolonged exposure to a head-down tilt position during long duration bed rest can resemble several effects of the microgravity environment such as reduced sensory inputs, body unloading and increased cephalic fluid distribution. The question of whether microgravity affects other central nervous system functions such as brain functional connectivity and its relationship with neurocognitive performance is largely unknown, but of potential importance to the health and performance of astronauts both during and post-flight. The aims of the present study are 1) to identify changes in sensorimotor resting state functional connectivity that occur with extended bed rest exposure, and to characterize their recovery time course; 2) to evaluate how these neural changes correlate with neurocognitive performance. Resting-state functional magnetic resonance imaging (rsfMRI) data were collected from 17 male participants. The data were acquired through the NASA bed rest facility, located at the University of Texas Medical Branch (Galveston, TX). Participants remained in bed with their heads tilted down six degrees below their feet for 70 consecutive days. RsfMRI data were obtained at seven time points: 7 and 12 days before bed rest; 7, 50, and 65 days during bed rest; and 7 and 12 days after bed rest. Functional connectivity magnetic resonance imaging (fcMRI) analysis was performed to measure the connectivity of sensorimotor networks in the brain before, during, and post-bed rest. We found a decrease in left putamen connectivity with the pre- and post-central gyri from pre bed rest to the last day in bed rest. In addition, vestibular cortex connectivity with the posterior cingulate cortex decreased from pre to post bed rest. Furthermore, connectivity between cerebellar right superior posterior fissure and other cerebellar regions decreased from pre bed rest to the last day in bed rest. In contrast, connectivity within the default mode network remained stable over the course of bed rest. We also utilized a battery of behavioral measures including spatial working memory tasks and measures of functional mobility and balance. These behavioral measurements were collected before, during, and after bed rest. We will report the preliminary findings of correlations observed between brain functional connectivity and behavioral performance changes. Our results suggest that sensorimotor brain networks exhibit decoupling with extended periods of reduced usage. The findings from this study could aid in the understanding and future design of targeted countermeasures to alleviate the detrimental health and neurocognitive effects of long-duration spaceflight.

Cassady, K.↗
NASA NTRS2015

3-D CFD Simulation and Validation of Oxygen-Rich Hydrocarbon Combustion in a Gas-Centered Swirl Coaxial Injector using a Flamelet-Based Approach

Injector design is a critical part of the development of a rocket Thrust Chamber Assembly (TCA). Proper detailed injector design can maximize propulsion efficiency while minimizing the potential for failures in the combustion chamber. Traditional design and analysis methods for hydrocarbon-fuel injector elements are based heavily on empirical data and models developed from heritage hardware tests. Using this limited set of data produces challenges when trying to design a new propulsion system where the operating conditions may greatly differ from heritage applications. Time-accurate, Three-Dimensional (3-D) Computational Fluid Dynamics (CFD) modeling of combusting flows inside of injectors has long been a goal of the fluid analysis group at Marshall Space Flight Center (MSFC) and the larger CFD modeling community. CFD simulation can provide insight into the design and function of an injector that cannot be obtained easily through testing or empirical comparisons to existing hardware. However, the traditional finite-rate chemistry modeling approach utilized to simulate combusting flows for complex fuels, such as Rocket Propellant-2 (RP-2), is prohibitively expensive and time consuming even with a large amount of computational resources. MSFC has been working, in partnership with Streamline Numerics, Inc., to develop a computationally efficient, flamelet-based approach for modeling complex combusting flow applications. In this work, a flamelet modeling approach is used to simulate time-accurate, 3-D, combusting flow inside a single Gas Centered Swirl Coaxial (GCSC) injector using the flow solver, Loci-STREAM. CFD simulations were performed for several different injector geometries. Results of the CFD analysis helped guide the design of the injector from an initial concept to a tested prototype. The results of the CFD analysis are compared to data gathered from several hot-fire, single element injector tests performed in the Air Force Research Lab EC-1 test facility located at Edwards Air Force Base.

Richardson, Brian↗
NASA NTRS2016

Space Launch System Spacecraft and Payload Elements: Making Progress Toward First Launch

Significant and substantial progress continues to be accomplished in the design, development, and testing of the Space Launch System (SLS), the most powerful human-rated launch vehicle the United States has ever undertaken. Designed to support human missions into deep space, SLS is one of three programs being managed by the National Aeronautics and Space Administration's (NASA's) Exploration Systems Development directorate. The Orion spacecraft program is developing a new crew vehicle that will support human missions beyond low Earth orbit, and the Ground Systems Development and Operations (GSDO) program is transforming Kennedy Space Center (KSC) into next-generation spaceport capable of supporting not only SLS but also multiple commercial users. Together, these systems will support human exploration missions into the proving ground of cislunar space and ultimately to Mars. SLS will deliver a near-term heavy-lift capability for the nation with its 70 metric ton Block 1 configuration, and will then evolve to an ultimate capability of 130 metric tons. The SLS program marked a major milestone with the successful completion of the Critical Design Review in which detailed designs were reviewed and subsequently approved for proceeding with full-scale production. This marks the first time an exploration class vehicle has passed that major milestone since the Saturn V vehicle launched astronauts in the 1960s during the Apollo program. Each element of the vehicle now has flight hardware in production in support of the initial flight of the SLS - Exploration Mission-1 (EM-1), an uncrewed mission to orbit the moon and return, and progress in on track to meet the initial targeted launch date in 2018. In Utah and Mississippi, booster and engine testing are verifying upgrades made to proven shuttle hardware. At Michoud Assembly Facility (MAF) in Louisiana, the world's largest spacecraft welding tool is producing tanks for the SLS core stage. This paper will particularly focus on work taking place at Marshall Space Flight Center (MSFC) and United Launch Alliance (ULA) in Alabama, where upper stage and adapter elements of the vehicle are being constructed and tested. Providing the Orion crew capsule/launch vehicle interface and in-space propulsion via a cryogenic upper stage, the Spacecraft/Payload Integration and Evolution (SPIE) Element serves a key role in achieving SLS goals and objectives. The SPIE element marked a major milestone in 2014 with the first flight of original SLS hardware, the Orion Stage Adapter (OSA) which was used on Exploration Flight Test-1 with a design that will be used again on EM-1. Construction is already underway on the EM-1 Interim Cryogenic Propulsion Stage (ICPS), an in-space stage derived from the Delta Cryogenic Second Stage. Manufacture of the Orion Stage Adapter and the Launch Vehicle Stage Adapter is set to begin at the Friction Stir Facility located at MSFC while structural test articles are either completed (OSA) or nearing completion (Launch Vehicle Stage Adapter). An overview is provided of the launch vehicle capabilities, with a specific focus on SPIE Element qualification/testing progress, as well as efforts to provide access to deep space regions currently not available to the science community through a secondary payload capability utilizing CubeSat-class satellites.

Schorr, Andrew A.↗
NASA NTRS2016

Space Launch System Spacecraft and Payload Elements: Making Progress Toward First Launch

Significant and substantial progress continues to be accomplished in the design, development, and testing of the Space Launch System (SLS), the most powerful human-rated launch vehicle the United States has ever undertaken. Designed to support human missions into deep space, SLS is one of three programs being managed by the National Aeronautics and Space Administration's (NASA's) Exploration Systems Development directorate. The Orion spacecraft program is developing a new crew vehicle that will support human missions beyond low Earth orbit, and the Ground Systems Development and Operations program is transforming Kennedy Space Center into next-generation spaceport capable of supporting not only SLS but also multiple commercial users. Together, these systems will support human exploration missions into the proving ground of cislunar space and ultimately to Mars. SLS will deliver a near-term heavy-lift capability for the nation with its 70 metric ton (t) Block 1 configuration, and will then evolve to an ultimate capability of 130 t. The SLS program marked a major milestone with the successful completion of the Critical Design Review in which detailed designs were reviewed and subsequently approved for proceeding with full-scale production. This marks the first time an exploration class vehicle has passed that major milestone since the Saturn V vehicle launched astronauts in the 1960s during the Apollo program. Each element of the vehicle now has flight hardware in production in support of the initial flight of the SLS -- Exploration Mission-1 (EM-1), an un-crewed mission to orbit the moon and return. Encompassing hardware qualification, structural testing to validate hardware compliance and analytical modeling, progress in on track to meet the initial targeted launch date in 2018. In Utah and Mississippi, booster and engine testing are verifying upgrades made to proven shuttle hardware. At Michoud Assembly Facility in Louisiana, the world's largest spacecraft welding tool is producing tanks for the SLS core stage. This paper will particularly focus on work taking place at Marshall Space Flight Center (MSFC) and United Launch Alliance in Alabama, where upper stage and adapter elements of the vehicle are being constructed and tested. Providing the Orion crew capsule/launch vehicle interface and in-space propulsion via a cryogenic upper stage, the Spacecraft/Payload Integration and Evolution (SPIE) Element serves a key role in achieving SLS goals and objectives. The SPIE element marked a major milestone in 2014 with the first flight of original SLS hardware, the Orion Stage Adapter (OSA) which was used on Exploration Flight Test-1 with a design that will be used again on EM-1. Construction is already underway on the EM-1 Interim Cryogenic Propulsion Stage (ICPS), an in-space stage derived from the Delta Cryogenic Second Stage. Manufacture of the Orion Stage Adapter and the Launch Vehicle Stage Adapter is set to begin at the Friction Stir Facility located at MSFC while structural test articles are either completed (OSA) or nearing completion (Launch Vehicle Stage Adapter). An overview is provided of the launch vehicle capabilities, with a specific focus on SPIE Element qualification/testing progress, as well as efforts to provide access to deep space regions currently not available to the science community through a secondary payload capability utilizing CubeSat-class satellites.

Schorr, Andrew A.↗