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Time and Frequency-Domain Cross-Verification of SLS 6DOF Trajectory Simulations

The Space Launch System (SLS) Guidance, Navigation, and Control (GNC) team and its partners have developed several time- and frequency-based simulations for development and analysis of the proposed SLS launch vehicle. The simulations differ in fidelity and some have unique functionality that allows them to perform specific analyses. Some examples of the purposes of the various models are: trajectory simulation, multi-body separation, Monte Carlo, hardware in the loop, loads, and frequency domain stability analyses. While no two simulations are identical, many of the models are essentially six degree-of-freedom (6DOF) representations of the SLS plant dynamics, hardware implementation, and flight software. Thus at a high level all of those models should be in agreement. Comparison of outputs from several SLS trajectory and stability analysis tools are ongoing as part of the program's current verification effort. The purpose of these comparisons is to highlight modeling and analysis differences, verify simulation data sources, identify inconsistencies and minor errors, and ultimately to verify output data as being a good representation of the vehicle and subsystem dynamics. This paper will show selected verification work in both the time and frequency domain from the current design analysis cycle of the SLS for several of the design and analysis simulations. In the time domain, the tools that will be compared are MAVERIC, CLVTOPS, SAVANT, STARS, ARTEMIS, and POST 2. For the frequency domain analysis, the tools to be compared are FRACTAL, SAVANT, and STARS. The paper will include discussion of these tools including their capabilities, configurations, and the uses to which they are put in the SLS program. Determination of the criteria by which the simulations are compared (matching criteria) requires thoughtful consideration, and there are several pitfalls that may occur that can severely punish a simulation if not considered carefully. The paper will discuss these considerations and will present a framework for responding to these issues when they arise. For example, small event timing differences can lead to large differences in mass properties if the criteria are to measure those properties at the same time, or large differences in altitude if the criteria are to measure those properties when the simulation experiences a staging event. Similarly, a tiny difference in phase can lead to large gain margin differences for frequency-domain comparisons of gain margins.

Johnson, Matthew

Dual and Multi-Spectral Band SLS Infrared Camera Systems

Based on the recent success of our strained-layer superlattice (SLS)-based infrared (IR) camera that performed Earth imaging from the International Space Station (ISS) in 2019 we have built, what we consider, to be the next generation multi-band SLS imaging system. The Compact Thermal Imager (CTI) was installed on the Robotic Refueling Mission 3 (RRM3) and attached to the exterior of the ISS. From this location we were able to capture 15 million images of a multitude of fires around the globe in 2019. This unexpected trove of data initiated quite a bit of scientific interest to further utilize this imaging capability but would include features to more precisely monitor terrestrial fires and other surface phenomena. To this end, we developed a technique to install specific bandpass filters directly onto the SLS detector hybrid assembly. Utilizing this technique we have built a CTI-2 camera system with two filters, 4 and 11µm, and have made a second detector assembly with six filter bands from 4-12µm. This second system will also be used to supplement Landsat remote imaging monitoring approximate land surface temperatures, monitor evapotranspiration, sea ice and glacier dynamics. The CTI-2 camera is based on a 1,024x1,024 (1kx1k) format SLS detector hybridized to a FLIR ISC0404 readout integrated circuit (ROIC). The six band SLS focal plane array is based on the 640x512 FLIR ISC 9803 ROIC. This camera system is based on the Landsat 8 and 9 Thermal IR Sensors (TIRS) instrument and one of its purposes is to perform ground truthing for the Landsat 8/9 data at higher spectral resolution. Both Landsat TIRS instruments are dual band thermal IR sensors centered on 11 and 12µm (each with about a 1µm bandpass). Both of our SLS systems utilize a Ricor K548 cryocooler. To streamline costs and development time we used commercial optics and both commercial and custom NASA electronic components. A primary feature of these camera systems is the incorporation of specific filters to collect fire data at ~3.9µm and thermal data at ~11µm. The CTI-2 instrument is designed for 37 m /pixel spatial resolution from 410km orbit (ISS orbit). In this paper, we will present the design and performance of the focal plane, optics, electronics and mechanical structure of the dual‑band CTI-2 and the focal plane performance of the six‑band focal plane.

Murzy Jhabvala

Evaluating Liftoff Debris for NASA’s Space Launch System (SLS) Prior to the Artemis I Launch

The SLS Artemis I launch vehicle is the first of several planned Artemis launch vehicles, with a number of design differences from earlier NASA missions that incur liftoff debris risk to the mission. As a test vehicle, the Artemis I hardware also endured environments and tests not planned for future missions, which led to several additional factors contributing to an evolving liftoff debris risk to the SLS vehicle. This paper will summarize these risk factors and address the processes used to evaluate and communicate the risks to support a successful Artemis I launch. It will discuss how the evolving risks that were quantified and evaluated by a Cross-Program team of debris Subject Matter Experts to mitigate liftoff debris hazards and communicate updated risk to the SLS vehicle. This process was performed through the inaugural use of an SLS debris day-of-launch (DOL) standard operating procedure that will be used for subsequent Artemis missions. This paper addresses the risk of liftoff debris, debris released by the vehicle or from the launch pad during liftoff through vehicle tower clear. Expected liftoff debris is well understood from previous NASA programs’ experience and from tests of materials, processes and functions that are known to release liftoff debris. These expected sources were assessed and cleared well ahead of launch day. However, given the ever-changing schedules and environments, processes were in place to evaluate any additional potential liftoff debris risks identified during launch countdown. Although many of the Artemis vehicle hardware components are similar to those on the NASA Shuttle Program, there are important differences in the architecture of the Artemis I vehicle which require new assessments of liftoff debris risk for the Artemis missions. The more favorable Artemis crew module location and surfaces are far less vulnerable to debris impacts; however, the longer vehicle can result in higher liftoff debris impact energies to those components on the aft end of the vehicle. Additionally, the positional change of the RS-25 liquid engines to nearer the Booster nozzle exit plane along with the change in Booster throat plug design is a disadvantage to the overall liftoff debris risk which resulted in additional test and analysis efforts for evaluating the integrated vehicle debris risk. In spite of the comprehensive tests and analyses of Artemis I expected liftoff debris, a number of additional tests/processes were completed prior to the Artemis I mission that were required to support a complete understanding of a new launch vehicle, but increased the risk of releasing liftoff debris. The hardware endured several additional cryogenic loading cycles, including the Green Run tests at Stennis Space Center, Wet Dress Rehearsals at Kennedy Space Center, and multiple launch attempts. Each of these cycles induced stresses in the thermal protection system (TPS) materials, increasing the risk of damage to and release of the TPS. Additionally, induced and weather environmental factors that could increase the likelihood of debris release were significant. Vibrations and stresses in the TPS were induced by a required roll-back to the Vehicle Assembly Building before Hurricane Ian to protect the vehicle from damage by high winds. Wind damage and potential internal stresses to several outer mold line materials on the integrated SLS vehicle and mobile launcher were caused by weathering Hurricane Nicole at Pad 39B the week before launch. A thorough imagery scan of the vehicle was performed after each event and the damage observed was repaired, removed, or assessed and the risk to the mission evaluated. Mitigation of debris risk can occur by tests and analyses to show debris impacted components as damage tolerant, by new/improved processes for prevention of debris availability, or redesign. Risk mitigation processes for Artemis I-specific liftoff debris events and the development and use of the SLS debris day of launch (DOL) procedures that will be used for subsequent Artemis missions will be described.

Space Launch System

Evaluating Liftoff Debris for NASA’s Space Launch System (SLS) Prior to the Artemis I Launch

The SLS Artemis I launch vehicle is the first of several planned Artemis launch vehicles, with a number of design differences from earlier NASA missions that incur liftoff debris risk to the mission. As a test vehicle, the Artemis I hardware also endured environments and tests not planned for future missions, which led to several additional factors contributing to an evolving liftoff debris risk to the SLS vehicle. This paper will summarize these risk factors and address the processes used to evaluate and communicate the risks to support a successful Artemis I launch. It will discuss how the evolving risks that were quantified and evaluated by a Cross-Program team of debris Subject Matter Experts to mitigate liftoff debris hazards and communicate updated risk to the SLS vehicle. This process was performed through the inaugural use of an SLS debris day-of-launch (DOL) standard operating procedure that will be used for subsequent Artemis missions. This paper addresses the risk of liftoff debris, debris released by the vehicle or from the launch pad during liftoff through vehicle tower clear. Expected liftoff debris is well understood from previous NASA programs’ experience and from tests of materials, processes and functions that are known to release liftoff debris. These expected sources were assessed and cleared well ahead of launch day. However, given the ever-changing schedules and environments, processes were in place to evaluate any additional potential liftoff debris risks identified during launch countdown. Although many of the Artemis vehicle hardware components are similar to those on the NASA Shuttle Program, there are important differences in the architecture of the Artemis I vehicle which require new assessments of liftoff debris risk for the Artemis missions. The more favorable Artemis crew module location and surfaces are far less vulnerable to debris impacts; however, the longer vehicle can result in higher liftoff debris impact energies to those components on the aft end of the vehicle. Additionally, the positional change of the RS-25 liquid engines to nearer the Booster nozzle exit plane along with the change in Booster throat plug design is a disadvantage to the overall liftoff debris risk which resulted in additional test and analysis efforts for evaluating the integrated vehicle debris risk. In spite of the comprehensive tests and analyses of Artemis I expected liftoff debris, a number of additional tests/processes were completed prior to the Artemis I mission that were required to support a complete understanding of a new launch vehicle, but increased the risk of releasing liftoff debris. The hardware endured several additional cryogenic loading cycles, including the Green Run tests at Stennis Space Center, Wet Dress Rehearsals at Kennedy Space Center, and multiple launch attempts. Each of these cycles induced stresses in the thermal protection system (TPS) materials, increasing the risk of damage to and release of the TPS. Additionally, induced and weather environmental factors that could increase the likelihood of debris release were significant. Vibrations and stresses in the TPS were induced by a required roll-back to the Vehicle Assembly Building before Hurricane Ian to protect the vehicle from damage by high winds. Wind damage and potential internal stresses to several outer mold line materials on the integrated SLS vehicle and mobile launcher were caused by weathering Hurricane Nicole at Pad 39B the week before launch. A thorough imagery scan of the vehicle was performed after each event and the damage observed was repaired, removed, or assessed and the risk to the mission evaluated. Mitigation of debris risk can occur by tests and analyses to show debris impacted components as damage tolerant, by new/improved processes for prevention of debris availability, or redesign. Risk mitigation processes for Artemis I-specific liftoff debris events and the development and use of the SLS debris day of launch (DOL) procedures that will be used for subsequent Artemis missions will be described.

Space Launch System

Successful First Flight of NASA’s SLS (Space Launch System) Super Heavy-Lift Rocket Lays Groundwork for U. S.’s Most Ambitious Missions

In late 2022, NASA’s SLS (Space Launch System) super heavy-lift rocket launched for the first time. Artemis I sent an uncrewed Orion spacecraft on a 25.5-day round-trip mission to lunar orbit. The near-perfect performance laid the groundwork for the next flights and for NASA’s return of humans to the Moon. The SLS team is now preparing for the launch of Artemis II, which will be the first launch of astronauts to cislunar space since Apollo 17 in December 1972. In addition to preparations on the Artemis II launch vehicle, significant progress is being made on the hardware and software for future flights. Artemis II will include a test of a new military-grade GPS system, which will be fully utilized on Artemis III. Progress is also being made on the exploration upper stage (EUS) for the Block 1B SLS variant, which will debut on Artemis IV. New production RS-25 liquid-propellant engines will be used beginning with Artemis V. These new engines, which are in a final qualification test firing program at the time of writing, realize a cost savings of at least 30 percent and reduced production time due to streamlined manufacturing and advances in technology, including additive manufacturing. The evolved solid rocket boosters, which will debut on Artemis IX as part of the Block 2 variant, are in development now. In addition to propulsion updates, each variant of SLS maintains payload configuration flexibility and can fly crew-only, cargo-only, and crew-cargo combinations. This adaptability ensures that SLS, with its significant mass and volume capability – including the ability to launch large co-manifested payloads with Orion directly to trans-lunar injection (TLI) – can support the country’s most ambitious missions. Results from the Artemis I mission, as well as progress to the next flights and SLS variants, will be covered in the paper and presentation.

Bruce R. Askins

Successful First Flight of NASA’s SLS (Space Launch System) Super Heavy-Lift Rocket: Laying Groundwork for U. S.’s Most Ambitious Missions

In late 2022, NASA’s SLS (Space Launch System) super heavy-lift rocket launched for the first time. Artemis I sent an uncrewed Orion spacecraft on a 25.5-day round-trip mission to lunar orbit. The near-perfect performance laid the groundwork for the next flights and for NASA’s return of humans to the Moon. The SLS team is now preparing for the launch of Artemis II, which will be the first launch of astronauts to cislunar space since Apollo 17 in December 1972. In addition to preparations on the Artemis II launch vehicle, significant progress is being made on the hardware and software for future flights. Artemis II will include a test of a new military-grade GPS system, which will be fully utilized on Artemis III. Progress is also being made on the exploration upper stage (EUS) for the Block 1B SLS variant, which will debut on Artemis IV. New production RS-25 liquid-propellant engines will be used beginning with Artemis V. These new engines, which are in a final qualification test firing program at the time of writing, realize a cost savings of at least 30 percent and reduced production time due to streamlined manufacturing and advances in technology, including additive manufacturing. The evolved solid rocket boosters, which will debut on Artemis IX as part of the Block 2 variant, are in development now. In addition to propulsion updates, each variant of SLS maintains payload configuration flexibility and can fly crew-only, cargo-only, and crew-cargo combinations. This adaptability ensures that SLS, with its significant mass and volume capability – including the ability to launch large co-manifested payloads with Orion directly to trans-lunar injection (TLI) – can support the country’s most ambitious missions. Results from the Artemis I mission, as well as progress to the next flights and SLS variants, will be covered in the paper and presentation.

Bruce Askins

NASA's Space Launch System (SLS) Program: Mars Program Utilization

NASA's Space Launch System is being designed for safe, affordable, and sustainable human and scientific exploration missions beyond Earth's orbit (BEO), as directed by the NASA Authorization Act of 2010 and NASA's 2011 Strategic Plan. This paper describes how the SLS can dramatically change the Mars program's science and human exploration capabilities and objectives. Specifically, through its high-velocity change (delta V) and payload capabilities, SLS enables Mars science missions of unprecedented size and scope. By providing direct trajectories to Mars, SLS eliminates the need for complicated gravity-assist missions around other bodies in the solar system, reducing mission time, complexity, and cost. SLS's large payload capacity also allows for larger, more capable spacecraft or landers with more instruments, which can eliminate the need for complex packaging or "folding" mechanisms. By offering this capability, SLS can enable more science to be done more quickly than would be possible through other delivery mechanisms using longer mission times.

May, Todd A.

SLS Flight Software Testing: Using a Modified Agile Software Testing Approach

NASA's Space Launch System (SLS) is an advanced launch vehicle for a new era of exploration beyond earth's orbit (BEO). The world's most powerful rocket, SLS, will launch crews of up to four astronauts in the agency's Orion spacecraft on missions to explore multiple deep-space destinations. Boeing is developing the SLS core stage, including the avionics that will control vehicle during flight. The core stage will be built at NASA's Michoud Assembly Facility (MAF) in New Orleans, LA using state-of-the-art manufacturing equipment. At the same time, the rocket's avionics computer software is being developed here at Marshall Space Flight Center in Huntsville, AL. At Marshall, the Flight and Ground Software division provides comprehensive engineering expertise for development of flight and ground software. Within that division, the Software Systems Engineering Branch's test and verification (T&V) team uses an agile test approach in testing and verification of software. The agile software test method opens the door for regular short sprint release cycles. The idea or basic premise behind the concept of agile software development and testing is that it is iterative and developed incrementally. Agile testing has an iterative development methodology where requirements and solutions evolve through collaboration between cross-functional teams. With testing and development done incrementally, this allows for increased features and enhanced value for releases. This value can be seen throughout the T&V team processes that are documented in various work instructions within the branch. The T&V team produces procedural test results at a higher rate, resolves issues found in software with designers at an earlier stage versus at a later release, and team members gain increased knowledge of the system architecture by interfacing with designers. SLS Flight Software teams want to continue uncovering better ways of developing software in an efficient and project beneficial manner. Through agile testing, there has been increased value through individuals and interactions over processes and tools, improved customer collaboration, and improved responsiveness to changes through controlled planning. The presentation will describe agile testing methodology as taken with the SLS FSW Test and Verification team at Marshall Space Flight Center.

Bolton, Albanie T.

Space Launch System (SLS) Mission Planner's Guide

The purpose of this Space Launch System (SLS) Mission Planner's Guide (MPG) is to provide future payload developers/users with sufficient insight to support preliminary SLS mission planning. Consequently, this SLS MPG is not intended to be a payload requirements document; rather, it organizes and details SLS interfaces/accommodations in a manner similar to that of current Expendable Launch Vehicle (ELV) user guides to support early feasibility assessment. Like ELV Programs, once approved to fly on SLS, specific payload requirements will be defined in unique documentation.

Smith, David Alan

SLS Block 1-B and Exploration Upper Stage Navigation System Design

The SLS Block 1B vehicle is planned to extend NASA's heavy lift capability beyond the initial SLS Block 1 vehicle. The most noticeable change for this vehicle from SLS Block 1 is the swapping of the upper stage from the Interim Cryogenic Propulsion stage (ICPS), a modified Delta IV upper stage, to the more capable Exploration Upper Stage (EUS). As the vehicle evolves to provide greater lift capability and execute more demanding missions so must the SLS Integrated Navigation System to support those missions. The SLS Block 1 vehicle carries two independent navigation systems. The responsibility of the two systems is delineated between ascent and upper stage flight. The Block 1 navigation system is responsible for the phase of flight between the launch pad and insertion into Low-Earth Orbit (LEO). The upper stage system assumes the mission from LEO to payload separation. For the Block 1B vehicle, the two functions are combined into a single system intended to navigate from ground to payload insertion. Both are responsible for self-disposal once payload delivery is achieved. The evolution of the navigation hardware and algorithms from an inertial-only navigation system for Block 1 ascent flight to a tightly coupled GPS-aided inertial navigation system for Block 1-B is described. The Block 1 GN&C system has been designed to meet a LEO insertion target with a specified accuracy. The Block 1-B vehicle navigation system is designed to support the Block 1 LEO target accuracy as well as trans-lunar or trans-planetary injection accuracy. This is measured in terms of payload impact and stage disposal requirements. Additionally, the Block 1-B vehicle is designed to support human exploration and thus is designed to minimize the probability of Loss of Crew (LOC) through high-quality inertial instruments and Fault Detection, Isolation, and Recovery (FDIR) logic. The preliminary Block 1B integrated navigation system design is presented along with the challenges associated with meeting the design objectives. This paper also addresses the design considerations associated with the use of Block 1 and Commercial Off-the-Shelf (COTS) avionics for Block 1-B/EUS as part of an integrated vehicle suite for orbital operations.

Oliver, T. Emerson

SLS Model Based Design: A Navigation Perspective

The SLS Program has implemented a Model-based Design (MBD) and Model-based Requirements approach for managing component design information and system requirements. This approach differs from previous large-scale design efforts at Marshall Space Flight Center where design documentation alone conveyed information required for vehicle design and analysis and where extensive requirements sets were used to scope and constrain the design. The SLS Navigation Team is responsible for the Program-controlled Design Math Models (DMMs) which describe and represent the performance of the Inertial Navigation System (INS) and the Rate Gyro Assemblies (RGAs) used by Guidance, Navigation, and Controls (GN&C). The SLS Navigation Team is also responsible for navigation algorithms. The navigation algorithms are delivered for implementation on the flight hardware as a DMM. For the SLS Block 1B design, the additional GPS Receiver hardware model is managed as a DMM at the vehicle design level. This paper describes the models, and discusses the processes and methods used to engineer, design, and coordinate engineering trades and performance assessments using SLS practices as applied to the GN&C system, with a particular focus on the navigation components.

Oliver, T. Emerson

State-Based Behavior Modeling of the Integrated SLS-MPCV System

In NASA's effort to foster a human spaceflight capability beyond Earth's orbit, two space systems are being developed - the Space Launch System (SLS) and the Multi-Purpose Crew Vehicle (MPCV). As of this time, the interactions between the two systems during launch are not fully detailed. To remedy this situation, a Systems Engineering approach utilizing models was developed to investigate the behavior of the integrated SLS-MPCV stack during ascent and abort situations. Specifically, this innovative approach combines aspects of Model-Based Systems Engineering (MBSE) and state analysis to simultaneously model the physical, functional, and behavioral aspects of systems. This approach focuses solely on the interactions between the systems, leaving much of the internal workings of either system at a logical level (i.e., black box). By utilizing this newly defined approach, a behavior model for the integrated SLS-MPCV stack was developed, emphasizing only the subset of interactions between the systems that impact behavior. Finally, analysis is performed within the model to investigate requirements gaps and examine the execution times of key behaviors related to various ascent phases and abort scenarios. The work described in this paper is merely a portion of the outlined effort being undertaken for this project; only a segment of the SLS-MPCV system behavior will be described.

Space Launch System (SLS)

STS-40 Spacelab Life Sciences 1 (SLS-1): The first dedicated spacelab life sciences mission

Successful exploration of space depends on the health and well-being of people who travel and work there. For this reason, the National Aeronautics and Space Administration (NASA) has dedicated several Space Shuttle missions to examine how living and working in space affects the human body. Spacelab Life Sciences 1 (SLS-1) is the first of these missions. The main purpose of the SLS-1 mission is to study the mechanisms, magnitudes, and time courses of certain physiological changes that occur during space flight and to investigate the consequences of the body's adaptation to microgravity and readjustment to gravity upon return to Earth. How does space flight influence the heart and circulatory system, metabolic processes, the muscles and bones, and the cells? If responses to weightlessness are undesirable, how can they be prevented or controlled? Will the human body maintain its physical and chemical equilibrium during months aboard a space station and years-long missions to Mars? When crews return to Earth, what can they expect to experience as their bodies readjust to Earth's gravity? With the SLS-1 experiments, NASA is addressing some of these questions. Various aspects of the SLS-1 are discussed.

Source record

Space Launch System (SLS) Program Overview NASA Research Announcement (NRA) Advanced Booster (AB) Engineering Demonstration and Risk Reduction (EDRR) Industry Day

SLS is a national capability that empowers entirely new exploration for missions of national importance. Program key tenets are safety, affordability, and sustainability. SLS builds on a solid foundation of experience and current capacities to enable a timely initial capability and evolve to a flexible heavy-lift capability through competitive opportunities: (1) Reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS (2) Enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability and performance The road ahead promises to be an exciting journey for present and future generations, and we look forward to working with you to continue America fs space exploration.

May, Todd A.

NASA's Space Launch System (SLS): A New National Capability

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) will contribute a new national capability for human space flight and scientific missions to low- Earth orbit (LEO) and beyond. Exploration beyond Earth orbit will be an enduring legacy to future generations, confirming America s desire to explore, learn, and progress. The SLS Program, managed at NASA s Marshall Space Fight Center, will develop the heavy lift vehicle that will launch the Orion Multi-Purpose Crew Vehicle (MPCV), equipment, supplies, and science experiments for missions beyond Earth s orbit. This paper gives an overview of the SLS design and management approach against a backdrop of the missions it will empower. It will detail the plan to move from the computerized drawing board to the launch pad in the near term, as well as summarize the innovative approaches the SLS team is applying to deliver a safe, affordable, and sustainable long-range national capability.

May, Todd A.

SLS Trade Study 0058: Day of Launch (DOL) Wind Biasing

SLS heritage hardware and legacy designs have shown load exceedances at several locations during Design Analysis Cycles (DAC): MPCV Z bending moments; ICPS Electro-Mechanical Actuator (EMA) loads; Core Stage loads just downstream of Booster forward interface. SLS Buffet Loads Mitigation Task Team (BLMTT) tasked to study issue. Identified low frequency buffet load responses are a function of the vehicle's total angle of attack (AlphaTotal). SLS DOL Wind Biasing Trade team to analyze DOL wind biasing methods to limit maximum AlphaTotal in the M0.8 - 2.0 altitude region for EM-1 and EM-2 missions through investigating: Trajectory design process; Wind wavelength filtering options; Launch availability; DOL process to achieve shorter processing/uplink timeline. Trade Team consisted of personnel supporting SLS, MPCV, GSDO programs.

Decker, Ryan K.

SLS-Derived Lab- Precursor to Deep Space Human Exploration

Plans to send humans to Mars are in the works and the launch system is being built. Are we ready? Transportation, entry, landing, and surface operations have been successfully demonstrated for robotic missions. However, for human missions, there are significant, potentially show-stopping issues. These issues, called Strategic Knowledge Gaps (SKGs), are the unanswered questions concerning long duration exploration Beyond low Earth Orbit (BEO). The gaps represent a risk of loss of life or mission and because they require extended exposure to the weightless environment outside of earth's protective geo-magnetic field, they cannot be resolved on Earth or on the International Space Station (ISS). Placing a laboratory at a relatively close and stable lunar Distant Retrograde Orbit (DRO) provides an accessible location with the requisite environmental conditions for conducting SKG research and testing mitigation solutions. Configurations comprised of multiple 3 m and 4.3 m diameter modules have been studied but the most attractive solution uses elements of the human Mars launch vehicle or Space Launch System (SLS) for a Mars proving ground laboratory. A shortened version of an SLS hydrogen propellant tank creates a Skylab-like pressure vessel that flies fully outfitted on a single launch. This not only offers significant savings by incorporating SLS pressure vessel development costs but avoids the expensive ISS approach using many launches with substantial on-orbit assembly before becoming operational. One of the most challenging SKGs is crew radiation protection; this is why SKG laboratory research is combined with Mars transit habitat systems development. Fundamentally, the two cannot be divorced because using the habitat systems for protection requires actual hardware geometry and material properties intended to contribute to shielding effectiveness. The SKGs are difficult problems. The solutions to these problems are not obvious; they require integrated, iterative, and multi-disciplinary development. A lunar DRO lab built from SLS elements enables an early and representative transit habitat test bed necessary for closing gaps before sending humans on a 1,000-day Mars mission.

Griffin, Brand M.

Use of Shuttle Heritage Hardware in Space Launch System (SLS) Application-Structural Assessment

NASA is moving forward with the development of the next generation system of human spaceflight to meet the Nation's goals of human space exploration. To meet these goals, NASA is aggressively pursuing the development of an integrated architecture and capabilities for safe crewed and cargo missions beyond low-Earth orbit. Two important tenets critical to the achievement of NASA's strategic objectives are Affordability and Safety. The Space Launch System (SLS) is a heavy-lift launch vehicle being designed/developed to meet these goals. The SLS Block 1 configuration (Figure 1) will be used for the first Exploration Mission (EM-1). It utilizes existing hardware from the Space Shuttle inventory, as much as possible, to save cost and expedite the schedule. SLS Block 1 Elements include the Core Stage, "Heritage" Boosters, Heritage Engines, and the Integrated Spacecraft and Payload Element (ISPE) consisting of the Launch Vehicle Stage Adapter (LVSA), the Multi-Purpose Crew Vehicle (MPCV) Stage Adapter (MSA), and an Interim Cryogenic Propulsion Stage (ICPS) for Earth orbit escape and beyond-Earth orbit in-space propulsive maneuvers. When heritage hardware is used in a new application, it requires a systematic evaluation of its qualification. In addition, there are previously-documented Lessons Learned (Table -1) in this area cautioning the need of a rigorous evaluation in any new application. This paper will exemplify the systematic qualification/assessment efforts made to qualify the application of Heritage Solid Rocket Booster (SRB) hardware in SLS. This paper describes the testing and structural assessment performed to ensure the application is acceptable for intended use without having any adverse impact to Safety. It will further address elements such as Loads, Material Properties and Manufacturing, Testing, Analysis, Failure Criterion and Factor of Safety (FS) considerations made to reach the conclusion and recommendation.

Aggarwal, Pravin