Building the RS-25 Engine for NASA’s Next Generation of Exploration.
NASA is aggressively pursuing a human lunar return to the Moon with the Artemis Program. The Space Launch System (SLS) is critical to the transportation architecture, providing both crew and cargo capability. To accelerate SLS development, NASA settled on space shuttle heritage propulsion technologies. Early missions will use repurposed RS-25 engines from the Shuttle Program adapted to SLS requirements. For future missions, however, NASA and engine contractor Aerojet Rocketdyne are restarting RS-25 production with a goal of using the latest manufacturing technologies to produce an RS-25 variant that will cost at least 30 percent less than the shuttle-era engines developed and flown for almost 30 years. The prospect of restarting the production line on these engines after many years and modifying the engine to reduce cost and better match the needs of the SLS vehicle presented unique challenges and opportunities for NASA and Aerojet Rocketdyne. NASA and AR are now deep into the process of adapting 16 RS-25 engines for the first four SLS Artemis flights and building the first RS-25 “Restart” engines for future Artemis missions. In addition to navigating programmatic, technical, and logistical challenges with the current RS-25 production work, NASA and AR have partnered to pursue new methods of building this engine through advanced manufacturing techniques to further reduce the cost and schedule required to build each RS-25 engine to contribute to the long-term affordability of the SLS vehicle. This presentation will discuss the goals for the restart program, the challenges, and results to date.