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NASA NTRS2017

Space Launch System Spacecraft and Payload Elements: Progress Toward Crewed Launch and Beyond

While significant and substantial progress continues to be accomplished toward readying the Space Launch System (SLS) rocket for its first test flight, work is already also underway on preparations for the second flight - using an upgraded version of the vehicle - and beyond. Designed to support human missions into deep space, Space Launch System (SLS), is the most powerful human-rated launch vehicle the United States has ever undertaken, and is one of three programs being managed by the National Aeronautics and Space Administration's (NASA's) Exploration Systems Development division. The Orion spacecraft program is developing a new crew vehicle that will support human missions beyond low Earth orbit (LEO), and the Ground Systems Development and Operations program is transforming Kennedy Space Center into a 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. For its first flight, SLS will deliver a near-term heavy-lift capability for the nation with its 70-metric-ton (t) Block 1 configuration. Each element of the vehicle now has flight hardware in production in support of the initial flight of the SLS, which will propel Orion around the moon and back. Encompassing hardware qualification, structural testing to validate hardware compliance and analytical modeling, progress in on track to meet the initial targeted launch date. 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. 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 the first flight of SLS. The element has overseen production of the Interim Cryogenic Propulsion Stage (ICPS), an in-space stage derived from the Delta Cryogenic Second Stage, which was manufactured at United Launch Alliance in Decatur, Alabama, prior to being shipped to Florida for flight preparations. Manufacture of the Orion Stage Adapter and the Launch Vehicle Stage Adapter (LVSA) took place at the Friction Stir Facility located at Marshall Space Flight Center in Huntsville, Alabama. Marshall is also home to the Integrated Structural Test of the ICPS, LVSA, and OSA, subjecting the stacked components to simulated stresses of launch. The SPIE Element is also overseeing integration of 13 "CubeSat" secondary payloads that will fly on the first flight of SLS, providing access to deep space regions in a way currently not available to the science community. At the same time as this preparation work is taking place toward the first launch of SLS, however, the Space Launch System Program is actively working toward its second launch. For its second flight, SLS will be upgraded to the more-capable Block 1B configuration. While the Block 1 configuration is capable of delivering more than 70 metric tons to low Earth orbit, the Block 1B vehicle will increase that capability to 105 t. For that flight, the new configuration introduces two major new elements to the vehicle - an Exploration Upper Stage (EUS) that will be used for both ascent and in-space propulsion, and a Universal Stage Adapter (USA) that serves as a "payload bay" for the rocket, allowing the launch of large exploration systems along with the Orion spacecraft. Already, flight hardware is being prepared for the Block 1B vehicle. Welding is taking place on the second rocket's core stage. Flight hardware production has begun on booster components. An RS-25 engine slated for that flight has been tested. Development work is taking place on the Exploration Upper Stage, with contracts in place for both the stage and the RL10 engines which will power it. (The EUS will use four RL10 engines, an increase from one on the ICPS.) For the crew configuration of the Block 1B vehicle, the SLS SPIE element is managing the USA and accompanying Payload Adapter, which will accommodate both large payloads co-manifested with Orion and small-satellite secondary payloads. This co-manifested payload capacity will be instrumental for missions into the Proving Ground around the moon, where NASA will test new systems and demonstrate new capabilities needed for human exploration farther into deep space.

Schorr, Andrew A.↗
NASA NTRS2012

NASA's Space Launch System: Affordability for Sustainability

The National Aeronautics and Space Administration's (NASA) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is charged with delivering a new capability for human exploration beyond Earth orbit in an austere economic climate. But the SLS value is clear and codified in United States (U.S.) budget law. The SLS Program knows that affordability is the key to sustainability and will provide an overview of initiatives designed to fit within the funding guidelines by using existing engine assets and hardware now in testing to meet a first launch by 2017 within the projected budget. It also has a long-range plan to keep the budget flat, yet evolve the 70-tonne (t) initial lift capability to 130-t lift capability after the first two flights. To achieve the evolved configuration, advanced technologies must offer appropriate return on investment to be selected through the competitive process. For context, the SLS will be larger than the Saturn V that took 12 men on 6 trips for a total of 11 days on the lunar surface some 40 years ago. Astronauts train for long-duration voyages on platforms such as the International Space Station, but have not had transportation to go beyond Earth orbit in modern times, until now. To arrive at the launch vehicle concept, the SLS Program conducted internal engineering and business studies that have been externally validated by industry and reviewed by independent assessment panels. In parallel with SLS concept studies, NASA is now refining its mission manifest, guided by U.S. space policy and the Global Exploration Roadmap, which reflects the mutual goals of a dozen member nations. This mission planning will converge with a flexible heavy-lift rocket that can carry international crews and the air, water, food, and equipment they need for extended trips to asteroids and Mars. In addition, the SLS capability will accommodate very large science instruments and other payloads, using a series of modular fairings and adapters to configure the rocket for the mission. The SLS affordability plan includes streamlining interfaces, applying risk-based insight into contracted work, centralizing systems engineering and integration, and nurturing a learning culture where the question Why? is often asked and the answer "Because we've always done it that way" is rarely heard. The SLS Program will deliver affordable space transportation solutions for the Orion Multi-Purpose Cargo Vehicle s first autonomous certification flight in 2017, followed by a crewed flight in 2021. As this briefing will show, the SLS will offer a global infrastructure asset for robotic and human scouts of all nations.

May, Todd A.↗
NASA NTRS2012

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.↗
NASA NTRS2017

NASA'S Space Launch System: Progress Toward the Proving Ground

With significant and substantial progress being accomplished toward readying the Space Launch System (SLS) rocket for its first test flight, work is already also underway on preparations for the second flight – using an upgraded version of the vehicle – and beyond. Designed to support human missions into deep space, Space Launch System (SLS), is the most powerful human-rated launch vehicle the United States has ever undertaken, and together with the Orion spacecraft will support human exploration missions into the proving ground of cislunar space and ultimately to Mars. For its first flight, SLS will deliver a near-term heavy-lift capability for the nation with its 70-metric-ton Block 1 configuration. Each element of the vehicle now has flight hardware in production in support of the initial flight of the SLS, which will propel Orion around the moon and back. For its second flight, SLS will be upgraded to the more-capable Block 1B configuration. While the Block 1 configuration is capable of delivering more than 70 metric tons to low Earth orbit, the Block 1B vehicle will increase that capability to 105 metric tons. For that flight, the new configuration introduces two major new elements to the vehicle – an Exploration Upper Stage (EUS) that will be used for both ascent and in-space propulsion, and a Universal Stage Adapter (USA) that serves as a “payload bay” for the rocket, allowing the launch of large exploration systems along with the Orion spacecraft. Already, flight hardware is being prepared for the Block 1B vehicle. Beyond the second flight, additional upgrades will be made to the vehicle. The Block 1B vehicle will also be able to launch 8.4-meter-diameter payload fairings, larger than any previously flown, and the Spacecraft Payload Integration and Evolution (SPIE) Element will oversee development and production of those fairings. Ultimately, SLS will be evolved to a Block 2 configuration, which will replace the solid rocket boosters on the Block 1 and 1B vehicles with more powerful boosters, and will be capable of delivering at least 130 metric tons to LEO. The Block 2 vehicle will be capable of launching even larger 10-meter diameter fairings, which will enable human mission of Mars. With these fairings, the Block 1B and 2 configurations of SLS will also be enabling for a wide variety of other payloads. 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, producing earlier data return, enhancing iterative exploration, and reducing mission cost and risk. 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, and offers the ability to conduct crewed servicing missions to observatories stationed at locations beyond low Earth orbit. This paper will provide a description of the SLS vehicle, and an overview of the vehicle’s capabilities and utilization potential.

Jackman, Angie↗
NASA NTRSDate not supplied

Green Run Modal Test of the NASA Space Launch System Core Stage

The Core Stage of the new NASA Space Launch System (SLS) is a 212-foot-tall rocket assembly—consisting primarily of two cryogenic propellant tanks, an engine section, and four RS-25 rocket engines—that will send crew and large payloads to the moon and beyond for NASA’s Artemis program. Prior to SLS assembly, the Core Stage completed a series of structural and functional tests in the B-2 Test Stand at Stennis Space Center, designated Green Run. The goal of Green Run was to verify analytical models, confirm proper subsystem operation, and test-fire all four RS-25 engines of the Core Stage. In January 2020, Green Run testing began with an experimental modal analysis test, performed by the Marshal Space Flight Center modal test team. A free-boundary test condition of the Core Stage was simulated as close as possible by suspending the massive launch vehicle from the B-2 Test Stand crane. Modal excitation was provided by a pair of 250-lb electro-dynamic shakers for multi-shaker random vibration testing, as well as a 12-pound instrumented hammer for impact testing. Modal response was measured with 550 accelerometer channels distributed on both the Core Stage and the B-2 Test Stand derrick crane. Following one very long day of testing, frequency response functions were calculated from the measured time histories in the target mode frequency range of 5 Hz to 15 Hz, and mode shapes, frequencies, and damping values were successfully estimated. The case-study presented in this paper will discuss Green Run, the SLS Core Stage, the modal test setup and execution, as well as a brief overview of the test results. Challenges associated with testing such a large, suspended structure in an outdoor environment will be discussed as well.

Space Launch System↗
NASA NTRS2013

NASA's Space Launch System: One Vehicle, Many Destinations

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is making progress toward delivering a new capability for exploration beyond Earth orbit. Developed with the goals of safety, affordability, and sustainability in mind, the SLS rocket will start its missions in 2017 with 10 percent more thrust than the Saturn V rocket that launched astronauts to the Moon 40 years ago. From there it will evolve into the most powerful launch vehicle ever flown, via an upgrade approach that will provide building blocks for future space exploration and development. The International Space Exploration Coordination Group, representing 12 of the world's space agencies, has created the Global Exploration Roadmap, which outlines paths toward a human landing on Mars, beginning with capability-demonstrating missions to the Moon or an asteroid. The Roadmap and corresponding NASA research outline the requirements for reference missions for all three destinations. This paper will explore the capability of SLS to meet those requirements and enable those missions. It will explain how the SLS Program is executing this development within flat budgetary guidelines by using existing engines assets and developing advanced technology based on heritage systems, from the initial 70 metric ton (t) lift capability through a block upgrade approach to an evolved 130-t capability. It will also detail the significant progress that has already been made toward its first launch in 2017. The SLS will offer a robust way to transport international crews and the air, water, food, and equipment they will need for extended trips to explore new frontiers. In addition, this paper will summarize the SLS rocket's capability to support science and robotic precursor missions to other worlds, or uniquely high-mass space facilities in Earth orbit. As this paper will explain, the SLS is making measurable progress toward becoming a global infrastructure asset for robotic and human scouts of all nations by providing the robust launch capability to deliver sustainable solutions for space exploration.

May, Todd A.↗
NASA NTRSDate not supplied

NASA Space Launch System Completes Green Run Testing, Begins Assembly

NASA’s Space Launch System (SLS) Program is poised in 2021 to shift its focus to the launch site with the completion of its last major integrated hardware and software test. SLS is NASA’s evolvable super heavy-lift launch vehicle for deep space exploration. Using proven propulsion technologies, SLS will be the most powerful launch vehicle in the world. That capability translates not only into more mass and volume to destinations but also simplified payload design and mission operations and greater opportunity for mission success. These capabilities will be important for the Artemis program, NASA’s plan to return humans to the Moon to stay in a sustainable way in order to develop and test technologies and operations needed for human missions to Mars and other destinations. SLS will anchor the transportation leg of an innovative, sustainable program of lunar exploration with commercial and international partners as the first step of human exploration of deep space. While all major hardware and software efforts made significant progress in 2020 and 2021, the most visible was the Green Run test series of the Artemis I core stage conducted at NASA’s Stennis Space Center (SSC) on the B-2 test stand. The series validated core stage design, performance, workmanship, and readiness for shipment to NASA Kennedy Space Center (KSC) for final processing, integration and launch. The core stage provides the backbone for SLS’ main propulsion system, consisting of two five-segment solid rocket boosters and four RS-25 liquid hydrogen (LH2)/liquid oxygen (LOX) engines. SLS also includes an Interim Cryogenic Propulsion Stage (ICPS) that will insert the Orion crew spacecraft into a lunar trajectory.

John Honeycutt↗
NASA NTRS2013

NASA's Space Launch System: Moving Toward the Launch Pad

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is making progress toward delivering a new capability for human space flight and scientific missions beyond Earth orbit. Developed with the goals of safety, affordability, and sustainability in mind, the SLS rocket will launch the Orion Multi-Purpose Crew Vehicle (MPCV), equipment, supplies, and major science missions for exploration and discovery. Supporting Orion's first autonomous flight to lunar orbit and back in 2017 and its first crewed flight in 2021, the SLS will evolve into the most powerful launch vehicle ever flown, via an upgrade approach that will provide building blocks for future space exploration and development. NASA is working to develop this new capability in an austere economic climate, a fact which has inspired the SLS team to find innovative solutions to the challenges of designing, developing, fielding, and operating the largest rocket in history. This paper will summarize the planned capabilities of the vehicle, the progress the SLS program has made in the 2 years since the Agency formally announced its architecture in September 2011, and the path the program is following to reach the launch pad in 2017 and then to evolve the 70 metric ton (t) initial lift capability to 130-t lift capability. The paper will explain how, to meet the challenge of a flat funding curve, an architecture was chosen which combines the use and enhancement of legacy systems and technology with strategic new development projects that will evolve the capabilities of the launch vehicle. This approach reduces the time and cost of delivering the initial 70 t Block 1 vehicle, and reduces the number of parallel development investments required to deliver the evolved version of the vehicle. The paper will outline the milestones the program has already reached, from developmental milestones such as the manufacture of the first flight hardware and the record-breaking testing of the J-2X engine, to life-cycle milestones such as the vehicle's Preliminary Design Review. The paper will also discuss the remaining challenges in both delivering the 70 t vehicle and in evolving its capabilities to the 130 t vehicle, and how the program plans to accomplish these goals. As this paper will explain, SLS is making measurable progress toward becoming a global infrastructure asset for robotic and human scouts of all nations by harnessing business and technological innovations to deliver sustainable solutions for space exploration

Creech, Stephen D.↗
NASA NTRS2013

NASA's Space Launch System: Moving Toward the Launch Pad

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center (MSFC), is making progress toward delivering a new capability for human space flight and scientific missions beyond Earth orbit. Designed with the goals of safety, affordability, and sustainability in mind, the SLS rocket will launch the Orion Multi-Purpose Crew Vehicle (MPCV), equipment, supplies, and major science missions for exploration and discovery. Supporting Orion's first autonomous flight to lunar orbit and back in 2017 and its first crewed flight in 2021, the SLS will evolve into the most powerful launch vehicle ever flown via an upgrade approach that will provide building blocks for future space exploration. NASA is working to deliver this new capability in an austere economic climate, a fact that has inspired the SLS team to find innovative solutions to the challenges of designing, developing, fielding, and operating the largest rocket in history. This paper will summarize the planned capabilities of the vehicle, the progress the SLS Program has made in the 2 years since the Agency formally announced its architecture in September 2011, the path it is following to reach the launch pad in 2017 and then to evolve the 70 metric ton (t) initial lift capability to 130-t lift capability after 2021. The paper will explain how, to meet the challenge of a flat funding curve, an architecture was chosen that combines the use and enhancement of legacy systems and technology with strategic new developments that will evolve the launch vehicle's capabilities. This approach reduces the time and cost of delivering the initial 70 t Block 1 vehicle, and reduces the number of parallel development investments required to deliver the evolved 130 t Block 2 vehicle. The paper will outline the milestones the program has already reached, from developmental milestones such as the manufacture of the first flight hardware, to life-cycle milestones such as the vehicle's Preliminary Design Review (PDR). The paper will also discuss the remaining challenges both in delivering the 70-t vehicle and in evolving its capabilities to the 130-t vehicle, and how NASA plans to accomplish these goals. As this paper will explain, SLS is making measurable progress toward becoming a global infrastructure asset for robotic and human scouts of all nations by harnessing business and technological innovations to deliver sustainable solutions for space exploration.

Creech, Stephen D.↗
NASA NTRSDate not supplied

Green Run Modal Test of the NASA Space Launch System Core Stage

The Core Stage of the new NASA Space Launch System (SLS) is a 212-foot tall rocket assembly—consisting primarily of two fuel tanks, an engine section, and four RS-25 rocket engines—capable of sending crew and large payloads to the moon and beyond with 1.6 million pounds of thrust. Currently, the Core Stage is in the B2 Test Stand at Stennis Space Center, undergoing a series of structural and functional tests, designated the Green Run test series. The ultimate goal of Green Run is to verify analytical models and confirm proper subsystem operation of the Core Stage. In January 2020, Green Run testing began with an experimental modal analysis test performed by the Marshal Space Flight Center modal test team. The desired free boundary condition of the Core Stage was achieved by suspending the massive spacecraft from the B2 Test Stand crane. Modal excitation was provided by a pair of 250-lb electro-dynamic shakers for multi-shaker random vibration testing, as well as a 12-pound impact hammer for impact testing. Modal response was measured with 550 accelerometers channels distributed on both the Core Stage and the B2 Test Stand crane. Following one very long night of testing, frequency response functions were calculated from the measured time histories in the target mode frequency range of 2.5 Hz to 15 Hz, and mode shapes, frequencies, and damping values were successfully extracted. The case-study presented in this paper will discuss the SLS Core Stage, the modal test setup and procedure, as well as a brief overview of the test results. Challenges associated with testing such a large, suspended structure in an outdoor environment will be discussed as well.

Green Run↗
NASA NTRS2017

The NASA Space Launch System Program Systems Engineering Approach for Affordability

The National Aeronautics and Space Administration is currently developing the Space Launch System to provide the United States with a capability to launch large Payloads into Low Earth orbit and deep space. One of the development tenets of the SLS Program is affordability. One initiative to enhance affordability is the SLS approach to requirements definition, verification and system certification. The key aspects of this initiative include: 1) Minimizing the number of requirements, 2) Elimination of explicit verification requirements, 3) Use of certified models of subsystem capability in lieu of requirements when appropriate and 4) Certification of capability beyond minimum required capability. Implementation of each aspect is described and compared to a "typical" systems engineering implementation, including a discussion of relative risk. Examples of each implementation within the SLS Program are provided.

Hutt, John J.↗
NASA NTRS2017

NASA's Space Launch System: Enabling Exploration and Discovery

As NASA's new Space Launch System (SLS) launch vehicle continues to mature toward its first flight and beyond, so too do the agency's plans for utilization of the rocket. Substantial progress has been made toward the production of the vehicle for the first flight of SLS - an initial "Block 1" configuration capable of delivering more than 70 metric tons (t) to Low Earth Orbit (LEO). That vehicle will be used for an uncrewed integrated test flight, propelling NASA's Orion spacecraft into lunar orbit before it returns safely to Earth. Flight hardware for that launch is being manufactured at facilities around the United States, and, in the case of Orion's service module, beyond. At the same time, production has already begun on the vehicle for the second SLS flight, a more powerful Block 1B configuration capable of delivering more than 105 t to LEO. This configuration will be used for crewed launches of Orion, sending astronauts farther into space than anyone has previously ventured. The 1B configuration will introduce an Exploration Upper Stage, capable of both ascent and in-space propulsion, as well as a Universal Stage Adapter - a payload bay allowing the flight of exploration hardware with Orion - and unprecedentedly large payload fairings that will enable currently impossible spacecraft and mission profiles on uncrewed launches. The Block 1B vehicle will also expand on the initial configuration's ability to deploy CubeSat secondary payloads, creating new opportunities for low-cost access to deep space. Development work is also underway on future upgrades to SLS, which will culminate in about a decade in the Block 2 configuration, capable of delivering 130 t to LEO via the addition of advanced boosters. As the first SLS draws closer to launch, NASA continues to refine plans for the human deep-space exploration it will enable. Planning currently focuses on use of the vehicle to assemble a Deep Space Gateway, which would comprise a habitat in the lunar vicinity allowing astronauts to gain experience living and working in deep space, a testbed for new systems and capabilities needed for exploration beyond, and a departure point for NASA and partners to send missions to other destinations. Assembly of the Gateway would be followed by a Deep Space Transport, which would be a vehicle capable of carrying astronauts farther into our solar system and eventually to Mars. This paper will give an overview of SLS' current status and its capabilities, and discuss current utilization planning.

Schorr, Andrew↗
NASA NTRS2017

NASA's Space Launch System: Enabling Exploration and Discovery

As NASA's new Space Launch System (SLS) launch vehicle continues to mature toward its first flight and beyond, so too do the agency's plans for utilization of the rocket. Substantial progress has been made toward the production of the vehicle for the first flight of SLS - an initial "Block 1" configuration capable of delivering more than 70 metric tons (t) to Low Earth Orbit (LEO). That vehicle will be used for an uncrewed integrated test flight, propelling NASA's Orion spacecraft into lunar orbit before it returns safely to Earth. Flight hardware for that launch is being manufactured at facilities around the United States, and, in the case of Orion's service module, beyond. At the same time, production has already begun on the vehicle for the second SLS flight, a more powerful Block 1B configuration capable of delivering more than 105 metric tons to LEO. This configuration will be used for crewed launches of Orion, sending astronauts farther into space than anyone has previously ventured. The 1B configuration will introduce an Exploration Upper Stage, capable of both ascent and in-space propulsion, as well as a Universal Stage Adapter - a payload bay allowing the flight of exploration hardware with Orion - and unprecedentedly large payload fairings that will enable currently impossible spacecraft and mission profiles on uncrewed launches. The Block 1B vehicle will also expand on the initial configuration's ability to deploy CubeSat secondary payloads, creating new opportunities for low-cost access to deep space. Development work is also underway on future upgrades to SLS, which will culminate in about a decade in the Block 2 configuration, capable of delivering 130 metric tons to LEO via the addition of advanced boosters. As the first SLS draws closer to launch, NASA continues to refine plans for the human deep-space exploration it will enable. Planning currently focuses on use of the vehicle to assemble a Deep Space Gateway, which would comprise a habitat in the lunar vicinity allowing astronauts to gain experience living and working in deep space, a testbed for new systems and capabilities needed for exploration beyond, and a departure point for NASA and partners to send missions to other destinations. Assembly of the Gateway would be followed by a Deep Space Transport, which would be a vehicle capable of carrying astronauts farther into our solar system and eventually to Mars. This paper will give an overview of SLS' current status and its capabilities, and discuss current utilization planning.

Robinson, Kimberly F.↗
NASA NTRS2014

America's Next Great Ship: Space Launch System Core Stage Transitioning from Design to Manufacturing

The Space Launch System (SLS) Program is essential to achieving the Nation's and NASA's goal of human exploration and scientific investigation of the solar system. As a multi-element program with emphasis on safety, affordability, and sustainability, SLS is becoming America's next great ship of exploration. The SLS Core Stage includes avionics, main propulsion system, pressure vessels, thrust vector control, and structures. Boeing manufactures and assembles the SLS core stage at the Michoud Assembly Facility (MAF) in New Orleans, LA, a historical production center for Saturn V and Space Shuttle programs. As the transition from design to manufacturing progresses, the importance of a well-executed manufacturing, assembly, and operation (MA&O) plan is crucial to meeting performance objectives. Boeing employs classic techniques such as critical path analysis and facility requirements definition as well as innovative approaches such as Constraint Based Scheduling (CBS) and Cirtical Chain Project Management (CCPM) theory to provide a comprehensive suite of project management tools to manage the health of the baseline plan on both a macro (overall project) and micro level (factory areas). These tools coordinate data from multiple business systems and provide a robust network to support Material & Capacity Requirements Planning (MRP/CRP) and priorities. Coupled with these tools and a highly skilled workforce, Boeing is orchestrating the parallel buildup of five major sub assemblies throughout the factory. Boeing and NASA are transforming MAF to host state of the art processes, equipment and tooling, the most prominent of which is the Vertical Assembly Center (VAC), the largest weld tool in the world. In concert, a global supply chain is delivering a range of structural elements and component parts necessary to enable an on-time delivery of the integrated Core Stage. SLS is on plan to launch humanity into the next phase of space exploration.

Birkenstock, Benjamin↗
NASA NTRS2015

Space Launch System Co-Manifested Payload Options for Habitation

The Space Launch System (SLS) has a co-manifested payload capability that will grow over time as the launch vehicle matures and planned upgrades are implemented. The final configuration is planned to be capable of inserting a payload greater than 10 metric tons (mt) into a trans-lunar injection trajectory along with the crew in the Orion capsule and its service module. The co-manifested payload is located below the Orion and its service module in a 10 m high fairing similar to the way the Saturn launch vehicle carried the lunar lander below the Apollo command and service modules. Various approaches that utilize this comanifested payload capability to build up infrastructure in deep space have been explored in support of future asteroid, lunar, and Mars mission scenarios. This paper reports on the findings of the Advanced Concepts Office study team at NASA Marshall Space Flight Center (MSFC) working with the Advanced Exploration Systems Program on the Exploration Augmentation Module Project. It includes some of the possible options for habitation in the co-manifested payload volume of the SLS. Findings include a set of module designs that can be developed in 10 mt increments to support these co-manifested payload missions along with a comparison of this approach to a large-module payload flight configuration for the SLS.

Smitherman, David↗
NASA NTRS2017

NASA's Space Launch System: Progress Report

After more than four decades exploring the space environment from low Earth orbit and developing long-duration spaceflight operational experience with the International Space Station (ISS), NASA is once again preparing to send explorers into deep space. Development, test and manufacturing is now underway on the launch vehicle, the crew spacecraft and the ground processing and launch facilities to support human and robotic missions to the moon, Mars and the outer solar system. The enabling launch vehicle for these ambitious new missions is the Space Launch System (SLS), managed by NASA's Marshall Space Flight Center (MSFC). Since the program began in 2011, the design has passed Critical Design Review, and extensive development, test and flight hardware has been produced by every major element of the SLS vehicle. Testing continues on engines, boosters, tanks and avionics. While the program has experienced engineering challenges typical of a new development, it continues to make steady progress toward the first SLS mission in roughly two years and a sustained cadence of missions thereafter. This paper will discuss these and other technical and SLS programmatic successes and challenges over the past year and provide a preview of work ahead before first flight.

Cook, Jerry↗
NASA NTRS2015

Space Launch System Co-Manifested Payload Options for Habitation

The Space Launch System (SLS) has a co-manifested payload capability that will grow over time as the rocket matures and planned upgrades are implemented. The final configuration is planned to be capable of inserting a payload greater than 10 metric tons (mt) into a trans-lunar injection trajectory along with the crew in the Orion capsule and the service module. The co-manifested payload is located below the Orion and its service module in a 10-meter high fairing similar to the way the Saturn launch vehicle carried the lunar lander below the Apollo command and service modules. A variety of approaches have been explored that utilizes this co-manifested payload capability to build up infrastructure in deep space in support of future asteroid, lunar, and Mars mission scenarios. This paper is a report on the findings from the Advanced Concepts Office study team at the NASA Marshall Space Flight Center, working with the Advanced Exploration Systems Program on the Exploration Augmentation Module Project. It includes some of the possible options for habitation in the co-manifested payload volume on SLS. Findings include module designs that can be developed in 10mt increments to support these missions, including overall conceptual layouts, mass properties, and approaches for integration into various scenarios for near-term support of deep space habitat research and technology development, support to asteroid exploration, and long range support for Mars transfer flights.

Smitherman, David↗
NASA NTRS2014

NASA's Space Launch System Advanced Booster Development

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is making progress toward delivering a new capability for human space flight and scientific missions beyond Earth orbit. NASA is executing this development within flat budgetary guidelines by using existing engines assets and heritage technology to ready an initial 70 metric ton (t) lift capability for launch in 2017, and then employing a block upgrade approach to evolve a 130-t capability after 2021. A key component of the SLS acquisition plan is a three-phased approach for the first-stage boosters. The first phase is to expedite the 70-t configuration by completing development of the Space Shuttle heritage 5-segment solid rocket boosters (SRBs) for the initial flights of SLS. Since no existing boosters can meet the performance requirements for the 130-t class SLS, the next phases of the strategy focus on the eventual development of advanced boosters with an expected thrust class potentially double the current 5-segment solid rocket booster capability of 3.88 million pounds of thrust each. The second phase in the booster acquisition plan is the Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) effort, for which contracts were awarded beginning in 2012 after a full and open competition, with a stated intent to reduce risks leading to an affordable advanced booster. NASA has awarded ABEDRR contracts to four industry teams, which are looking into new options for liquid-fuel booster engines, solid-fuel-motor propellants, and composite booster structures. Demonstrations and/or risk reduction efforts were required to be related to a proposed booster concept directly applicable to fielding an advanced booster. This paper will discuss the status of this acquisition strategy and its results toward readying both the 70 t and 130 t configurations of SLS. The third and final phase will be a full and open competition for Design, Development, Test, and Evaluation (DDT&E) of the advanced boosters. These new boosters will enable the flexible path approach to deep space exploration, opening up vast opportunities for human missions to near-Earth asteroids and Mars. This evolved capability will offer large volume for science missions and payloads, will be modular and flexible, and will be right-sized for mission requirements.

Robinson, Kimberly F.↗