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NASA's Space Launch System: Deep-Space Opportunities for Smallsats
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Space Launch System: Enabling Deep Space Human Exploration to the Moon, Mars and Beyond!
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NASA's Space Launch System Begins Integration, Stacking in Preparation for Artemis I Launch
The Artemis era of human lunar exploration is nearing take-off as NASA’s new super heavy-lift launch vehicle, the Space Launch System (SLS), begins stack-ing and integration operations in mid-2020 at Kennedy Space Center (KSC) in Florida. With a planned upgrade path to progressively more powerful vehicles and availability in crew and cargo configurations, SLS provides a unique and flexible launch solution to send crew, large-scale infrastructure and robotic probes to deep space. The SLS Block 1 vehicle, the initial variant to fly, is optimized for lunar missions with a proven propulsion system consisting of four liquid hydrogen (LH2)/liquid oxygen (LOX)-fed RS-25 engines and twin five-segment solid rocket boosters (SRBs). The Block 1 vehicle can also be outfitted with an industry-standard 5 m-class payload fairing (the “cargo” configuration) and will launch at least 27 metric tons (t) of mass to trans-lunar injection (TLI). SLS is the backbone of NASA’s Artemis program, which will return the agency’s human spaceflight program to the Moon for the first time since 1972. For the Artemis I mission, SLS will send an uncrewed Orion spacecraft to TLI, where it will enter a distant retrograde lunar orbit and fly 38,000 nmi past the Moon – farther than any spacecraft built for humans has ever traveled. The SLS Block 1 vehicle for Artemis I completed manufacturing in 2019. Several elements, including the upper stage, have been delivered to the Exploration Ground Systems (EGS) program at KSC and are being prepped for integration and stack-ing. The five-segment solid rocket boosters – the largest and most powerful ever built for flight – are also complete. The booster motor segments for the Artemis I flight are scheduled to ship from prime contractor Northrop Grumman’s Utah facilities and begin stacking and integration at KSC in June 2020. The SLS core stage is the largest rocket stage NASA has ever built in terms of volume and height, and includes the avionics and the tanks that feed cryogenic propellant to the four RS-25s (formerly Space Shuttle Main Engines [SSMEs]). They have been modified with an updated controller and nozzle insulation to protect them from the hotter launch environment. The SLS core stage is currently being test-ed at NASA’s Stennis Space Center (SSC) in a series of “green run” tests to verify it meets design and performance requirements. Following the green run test series, which is scheduled to culminate with a full-duration hot-fire of the four RS-25 engines, the core stage will ship to KSC and be stacked between the sol-id rocket boosters in the Vehicle Assembly Building (VAB). Integration of the vehicle will continue with the upper stage, known as the Interim Cryogenic Propulsion Stage (ICPS) and the Launch Vehicle Stage Adapter (LVSA) on the core stage. Another adapter, the Orion Stage Adapter (OSA), connects SLS to Orion and provides housing for 13 6U CubeSat payloads manifested on Artemis I. The CubeSats will be released in deep space after Orion separates from the vehicle, and the flight marks the first ride share opportunity for independent small-sats to deep space. The second major SLS variant to come online, Block 1B, replaces the single-engine ICPS with a four-engine LH2/LOX Exploration Upper Stage (EUS). This more powerful upper stage, along with other vehicle up-grades, will enable the Block 1B vehicle to launch 38-42 t to TLI, depending on crew or cargo configuration. The final evolution of the vehicle, Block 2, will onramp evolved solid rocket boosters to increase mass to TLI to 43-46 t, de-pending on crew or cargo configuration. The Block 1B/Block 2 vehicles can be outfitted with an 8.4 m-diameter payload fairing in 19.1 m or 27.4 m lengths, to provide unprecedented volume for payloads. With the initial Block 1 vehicle completely manufactured and the core stage in final testing before shipping to KSC, the SLS Program and its industry partners have made significant progress manufacturing subsequent vehicles. For the second Block 1 vehicle, the solid rocket motor segments are complete, as are the RS-25 engines with controllers. All five major components of the Artemis II core stage – the forward skirt, LOX and LH2 tanks, intertank and engine section – are manufactured and technicians are installing subsystems at NASA’s rocket factory, Michoud Assembly Facility. The RL-10 engine for the Artemis II ICPS is complete and panels have been machined for its LH2 tank. In addition, panels are machined for the vehicle’s two adapters, with welding scheduled to begin in summer 2020. Flight hard-ware is also in production for the third SLS vehicle, with several booster motor segments cast. The pace of development on the EUS has increased, with the goal to complete Critical Design Review (CDR) in December 2020. Several EUS test rings have been machined at Michoud. The EUS is designed to exe-cute a variety of missions – human spaceflight, deployment of deep-space infra-structure, or high-C3 missions to the outer solar system – with crew and cargo configurations available beginning in the mid-2020s. The near-term goal for the nation’s powerful new space exploration asset, however, is to launch the Arte-mis program, and send the first woman and the next man to the lunar surface. At the Astrodynamics Specialist Conference, the SLS program will update the community on the progress of the initial Block 1 vehicle in final green run test-ing, integration and stacking. In addition, this paper will provide an update to the community on the manufacturing status of subsequent Block 1 and Block 1B vehicles.
Status of NASA's Space Launch System
NASA's Space Launch System (SLS) continued to make significant progress in 2015 and 2016, completing hardware and testing that brings NASA closer to a new era of deep space exploration. Programmatically, SLS completed Critical Design Review (CDR) in 2015. A team of independent reviewers concluded that the vehicle design is technically and programmatically ready to move to Design Certification Review (DCR) and launch readiness in 2018. Just five years after program start, every major element has amassed development and flight hardware and completed key tests that will lead to an accelerated pace of manufacturing and testing in 2016 and 2017. Key to SLS' rapid progress has been the use of existing technologies adapted to the new launch vehicle. The existing fleet of RS-25 engines is undergoing adaptation tests to prove it can meet SLS requirements and environments with minimal change. The four-segment shuttle-era booster has been modified and updated with a fifth propellant segment, new insulation, and new avionics. The Interim Cryogenic Upper Stage is a modified version of an existing upper stage. The first Block I SLS configuration will launch a minimum of 70 metric tons (t) of payload to low Earth orbit (LEO). The vehicle architecture has a clear evolutionary path to more than 100t and, ultimately, to 130t. Among the program's major 2015-2016 accomplishments were two booster qualification hotfire tests, a series of RS-25 adaptation hotfire tests, manufacturing of most of the major components for both core stage test articles and first flight tank, delivery of the Pegasus core stage barge, and the upper stage simulator. Renovations to the B-2 test stand for stage green run testing was completed at NASA Stennis Space Center. This year will see the completion of welding for all qualification and flight EM-1 core stage components and testing of flight avionics, completion of core stage structural test stands, casting of the EM-1 solid rocket motors, additional testing of RS-25 engines and flight engine controllers This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before the first flight of this new capability.
Payload Utilization in NASA's Space Launch System
A revitalized National Space Council has directed NASA to return to the moon, with a series of preparatory missions paving the way for eventual human exploration. NASA's new deep space exploration system -- the heavy-lift Space Launch System (SLS), the Orion crew spacecraft and revitalized launch facilities at Kennedy Space Center -- will enable NASA and its commercial and international partners to meet these goals for human deep space exploration. SLS will be the most capable launch vehicle for these efforts, with an initial Block 1 capability of at least 26 metric tons (t) to trans-lunar injection (TLI). A more powerful Block 1B, available in crew and cargo configurations, with have the power to loft more than 37 t to TLI; the ultimate Block 2 variant will lift more than 45 t to TLI. For payload utilization, the Block 1 vehicle will carry 13 6U CubeSats as secondary payloads while the Block 1B crew vehicle will provide as much volume as the space shuttle payload bay in a Universal Stage Adapter (USA). Block 1B cargo vehicles will offer 8.4 m fairings in 19.1 m and 27.4 m lengths, with enough volume to accommodate habitat modules and landers. For missions beyond the Earth-moon system, SLS offers greater characteristic energy (C3), enabling faster transit or heavier payloads to the outer planets. The first mission of SLS and Orion, launching no earlier than December 2019, will send Orion into lunar distant retrograde orbit (DRO) on an approximately 25-day shakedown cruise known as Exploration Mission-1 (EM-1), enabling NASA to verify and validate new systems before sending astronauts to deep space on the next exploration mission. The SLS program and its prime contractors have made significant progress toward first launch, with several major components of the vehicle completed and delivered to the Exploration Ground Systems (EGS) Program at Kennedy Space Center. Major forward work includes integrating tanks, engines and other major sections into the EM-1 core stage at Michoud Assembly Facility and then shipping the entire core stage assembly to Stennis Space Center. There, it will be installed in the refurbished B-2 test stand for a series of integrated stage tests culminating in a green run hotfire test. The Program's Spacecraft Payload Integration and Evolution (SPIE) Office, responsible for the in-space stage, adapters and payload interfaces, has largely completed its effort on the Block 1 vehicle and is supporting manufacture of the first Block 1B vehicle. This paper will provide an overview of the Block 1 vehicle, its expected capabilities, secondary payload accommodations and manufacturing status, including structural testing and the challenges of developing a new launch vehicle. A lookahead to the Block 1B vehicle and the payload utilization opportunities it will provide in the 2020s will also be discussed, including the unique capabilities of the vehicle.
Analysis of Proposed 2007-2008 Revisions to the Lightning Launch Commit Criteria for United States Space Launches
Ascending space vehicles are vulnerable to both natural and triggered lightning. Launches under the jurisdiction of the United States are generally subject to a set of rules called the Lightning Launch Commit Criteria (LLCC) (Krider etal., 1999; Krider etal., 2006). The LLCC protect both the vehicle and the public by assuring that the launch does not take place in conditions posing a significant risk of a lightning strike to the ascending vehicle. Such a strike could destroy the vehicle and its payload, thus causing failure of the mission while releasing both toxic materials and debris. To assure safety, the LLCC are conservative and sometimes they may seriously limit the ability of the launch operator to fly as scheduled even when conditions are benign. In order to safely reduce the number of launch scrubs and delays attributable to the LLCC, the Airborne Field Mill (ABFM II) program was undertaken in 2000 - 2001. The effort was directed to collecting detailed high-quality data on the electrical, microphysical, radar and meteorological properties of thunderstorm-associated clouds. Details may be found in Dye et al., 2007. The expectation was that this additional knowledge would provide a better physical basis for the LLCC and allow them to be revised to be less restrictive while remaining at least as safe. That expectation was fulfilled, leading to significant revisions to the LLCC in 2003 and 2005. The 2005 revisions included the application of a new radar-derived quantity called the Volume Averaged Height Integrated Radar Reflectivity (VAHIRR) in the rules governing flight through anvil clouds. VAHIRR is the product of the volume averaged radar reflectivity times the radardetermined cloud thickness. The reflectivity average extends horizontally 5 km west, east, south and north of a point along the flight track and vertically from the 0 C isotherm to the top of the radar cloud. This region is defined as the "Specified Volume". See Dye et al., 2006 and Merceret et al., 2006 for a more thorough description of VAHIRR. The units are dBZ km (not dBZ per kilometer) and the threshold is 10 dBZ km. It is safe to fly through an anvil cloud for which VAHIRR is below this threshold everywhere along the flight track as long as (1) the entire cloud within 5 nmi. (9.26 km) of the flight track is colder than 0 C, (2) the points at which VAHIRR must be evaluated are at least 20 km from any active convective cores and recent lightning, and (3) the radar return is not being attenuated within the Specified Volume around those points.
Analysis of Proposed 2007-2008 Revisions to the Lightning Launch Commit Criteria for United States Space Launches
Ascending space vehicles are vulnerable to both natural and triggered lightning. Launches under the jurisdiction of the United States are generally subject to a set of rules called the Lightning Launch Commit Criteria (LLCC). The LLCC protect both the vehicle and the public by assuring that the launch does not take place in conditions posing a significant risk of a lightning strike to the ascending vehicle. Such a strike could destroy the vehicle and its payload, thus causing failure of the mission while releasing both toxic materials and debris. To assure safety, the LLCC are conservative and sometimes they may seriously limit the ability of the launch operator to fly as scheduled even when conditions are benign. In order to safely reduce the number of launch scrubs and delays attributable to the LLCC, the Airborne Field Mill (ABFM) program was undertaken in 2000 - 2001. The effort was directed to collecting detailed high-quality data on the electrical, microphysical, radar and meteorological properties of thunderstorm-associated clouds. The expectation was that this additional knowledge would provide a better physical basis for the LLCC and allow them to be revised to be both safer and less restrictive. That expectation was fulfilled, leading to significant revisions to the LLCC in 2003 and 2005. The 2005 revisions included the application of a new radar-derived quantity called the Volume Averaged Height Integrated Radar Reflectivity (VAHIRR) in the rules governing flight through anvil clouds. Analysis of the ABFM data has continued, and two additional revisions to the LLCC were proposed in late 2006 for adoption in 2007 or 2008. One proposal was to apply the VAHIRR concept to debris clouds, and the other was to reduce the "stand-off distances" in the rules for anvil and/or debris clouds. The stand-off distance is the clearance (out side of the cloud) required between the flight path of the vehicle and the edge of a cloud that it is not permissible to fly through. This paper will discuss these proposed changes in the LLCC and the scientific rationale for adopting or rejecting them based on ABFM data.
Going Boldly Beyond: Progress on NASA's Space Launch System
NASA's Space Launch System is implementing an evolvable configuration approach to system development in a resource-constrained era. Legacy systems enable non-traditional development funding and contribute to sustainability and affordability. Limited simultaneous developments reduce cost and schedule risk. Phased approach to advanced booster development enables innovation and competition, incrementally demonstrating affordability and performance enhancements. Advanced boosters will provide performance for the most capable heavy lift launcher in history, enabling unprecedented space exploration benefiting all of humanity.
NASA's Space Launch System: A Transformative Capability for Deep Space Missions
Already making substantial progress toward its first launches, NASA’s Space Launch System (SLS) exploration-class launch vehicle presents game-changing new opportunities in spaceflight, enabling human exploration of deep space, as well as a variety of missions and mission profiles that are currently impossible. Today, the initial configuration of SLS, able to deliver more than 70 metric tons of payload to low Earth orbit (LEO), is well into final production and testing ahead of its planned first flight, which will send NASA’s new Orion crew vehicle around the moon and will deploy 13 CubeSats, representing multiple disciplines, into deep space. At the same time, production work is already underway toward the more-capable Block 1B configuration, planned to debut on the second flight of SLS, and capable of lofting 105 tons to LEO or of co-manifesting large exploration systems with Orion on launches to the lunar vicinity. Progress being made on the vehicle for that second flight includes initial welding of its core stage and testing of one of its engines, as well as development of new elements such as the powerful Exploration Upper Stage and the Universal Stage Adapter “payload bay.” Ultimately, SLS will evolve to a configuration capable of delivering more than 130 tons to LEO to support humans missions to Mars. In order to enable human deep-space exploration, SLS provides unrivaled mass, volume, and departure energy for payloads, offering numerous benefits for a variety of other missions. For robotic science probes to the outer solar system, for example, SLS can cut transit times to less than half that of currently available vehicles or substantially increased spacecraft mass. In the field of astrophysics, SLS’ high payload volume, in the form of payload fairings with a diameter of up to 10 meters, creates the opportunity for launch of large-aperture telescopes providing an unprecedented look at our universe. This presentation will give an overview of SLS’ capabilities and its current status, and discuss the vehicle’s potential for human exploration of deep space and other game-changing utilization opportunities.
Benefits to the Europa Clipper Mission Provided by the Space Launch System
The National Aeronautics and Space Administration's (NASA's) proposed Europa Clipper mission would provide an unprecedented look at the icy Jovian moon, and investigate its environment to determine the possibility that it hosts life. Focused on exploring the water, chemistry, and energy conditions on the moon, the spacecraft would examine Europa's ocean, ice shell, composition and geology by performing 32 low-altitude flybys of Europa from Jupiter orbit over 2.3 years, allowing detailed investigations of globally distributed regions of Europa. In hopes of expediting the scientific program, mission planners at NASA's Jet Propulsion Laboratory are working with the Space Launch System (SLS) program, managed at Marshall Space Flight Center. Designed to be the most powerful launch vehicle ever flown, SLS is making progress toward delivering a new capability for exploration beyond Earth orbit. The SLS rocket will offer an initial low-Earth-orbit lift capability of 70 metric tons (t) beginning with a first launch in 2017 and will then evolve into a 130 t Block 2 version. While the primary focus of the development of the initial version of SLS is on enabling human exploration missions beyond low Earth orbit using the Orion Multi-Purpose Crew Vehicle, the rocket offers unique benefits to robotic planetary exploration missions, thanks to the high characteristic energy it provides. This paper will provide an overview of both the proposed Europa Clipper mission and the Space Launch System vehicle, and explore options provided to the Europa Clipper mission for a launch within a decade by a 70 t version of SLS with a commercially available 5-meter payload fairing, through comparison with a baseline of current Evolved Expendable Launch Vehicle (EELV) capabilities. Compared to that baseline, a mission to the Jovian system could reduce transit times to less than half, or increase mass to more than double, among other benefits. In addition to these primary benefits, the paper will also explore secondary effects, such as the elimination of the need to design for hot inner-solar-system conditions and gain permits for a radioisotope thermoelectric generator fly-by of Earth, are provided by the use of a direct trajectory transit instead of a more time-consuming gravitational-assist trajectory.
The U.S. Commercial Space Launch Program and the Department of Defense Dilemma
The U.S. space launch program no longer dominates the world and is now playing 'catch-up' with the world's first commercial launch company, Arianespace. A healthy U.S. commercial launch program is essential and will assure continued low-cost military access to space. The effort to regain the lead in commercial space launch market has been hindered by declining Department of Defense budgets. President Clinton's space policy prohibits expensive new launch vehicles and limits the Department of Defense to low cost upgrades of existing launch vehicles. The U.S. government created the space sector and must ensure a smooth and effective split from the emerging commercial space program in order to regain world dominance. Until U.S. government and commercial ties are severed, the Department of Defense must consider commercial space launch interests when making military decisions. Ariane provides an excellent 'bench mark' for the U.S. to base future launch vehicle upgrades. Ariane advantages were identified and low-cost recommendations have been made. If the U.S. sets the target of first equaling and then surpassing Ariane by incorporating these recommendations, then the U.S. could once again dominate the world commercial launch market and ensure low cost military access to space.
NASA's Space Launch System: Progress Report
NASA and its commercial industry team achieved significant progress in 2016 in manufacturing and testing of the Block 1 vehicle for the first launch of the Space Launch System (SLS). Test and flight article hardware for the liquid hydrogen fuel tank as well as the engine section for the core stage were completed at Michoud Assembly Facility (MAF) in New Orleans. Test stands neared completion at Marshall Space Flight Center for the propellant tanks, engine section, intertank and payload section. Stennis Space Center completed major structural renovations on the B2 test stand, where the core stage "green run" test program will be conducted. The SLS team completed a hotfire test series at Stennis to successfully demonstrate the ability of the RS-25 engine to operate under SLS environments and performance conditions. The team also test fired the second qualification five-segment solid rocket motor and cast the first six motor segments for the first SLS mission. The Interim Cryogenic Propulsion Stage (ICPS) test article was delivered to Marshall for structural tests, and work is nearly finished on the flight stage. Flight software testing completed at Marshall included power quality and command and data handling. In 2017, that work continues. SLS completed Preliminary Design Review (PDR) on the Exploration Upper Stage (EUS), a powerful, human-rated spacecraft that will propel explorers to cis-lunar space. In 2017, hardware will continue to be integrated at MAF for core stage structural test articles and the first two operational flights. RS-25 hotfire testing will continue to explore engine performance, as well as test flight-like software and four new Engine Controller Units (ECUs) for the first mission. Production of development components for a more affordable RS-25 design is underway. Core stage structural test articles have begun arriving at Marshall. While engineering challenges typical of a new development are possible, SLS is working toward launch readiness in late 2018. This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before first flight