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Tight Fits for Americas Next Moon Rocket, Ares V

America has begun the development of a new heavy lift rocket which will enable humans to return to the moon and reach even farther destinations. Five decades ago, the National Aeronautics and Space Administration designed a system (called Saturn/Apollo) to carry men to the moon and back; the rocket which boosted them to the moon was the Saturn V. Saturn V was huge relative to contemporary rockets and is still the largest rocket ever launched. The new moon rocket is called Ares V. It will insert 40% more payload into low earth orbit than Saturn V; and after docking with the crew spacecraft, it will insert 50% more payload onto the translunar trajectory than Saturn V. The current design of Ares V calls for two liquid-fueled stages and 2 "strap-on" solid rockets. The solid rockets are extended-length versions of the solid rockets used on the Shuttle. The diameter of the liquid stages is at least as large as the first stage of the Saturn V; the height of the lower liquid stage (called the core stage) is longer than the external tank of the Shuttle. Huge rockets require huge infrastructure and, during the Saturn/Apollo era, America invested significantly in manufacturing, assembly and launch facilities which are still in use today. Since the Saturn/Apollo era, America has invested in additional infrastructure for the Shuttle program. Ares V must utilize this existing infrastructure, with reasonable modifications. Building a rocket with 50% more capability in the same buildings, testing it in the same test stands, shipping on the same canals under the same bridges, assembling it in the same building, rolling it to the pad on the same crawler, and launching it from the same launch pad is an engineering and logistics challenge which goes hand-in-hand with designing the structure, tanks, turbines, engines, software, etc. necessary to carry such a large payload to earth orbit and to the moon. This paper quantitatively discusses the significant "tight fits" that are constraining Ares V. The engineers designing and building the infrastructure for the Saturn/Apollo program usually added margins and growth capability; sometimes the size of existing facilities (such as the width of a draw bridge) was not a constraint. Ares V may utilize the "extra" space in the existing facilities and expand other tight fits. Some of the tight fits cannot be overcome without great expense; raising the roof on the Vertical Assembly Building for example. Other tight fits are easily overcome; the transporter at the manufacturing facility for the core stage can pass under low ceilings and later over a dike (without dragging the middle) by retracting or extending the struts which support the stage. Tight fits discussed in this paper include manufacturing (jigs, widths, heights, and local transportation), testing (test stand sizes and crane capability), transportation to the test stands and the launch site (barge, waterway, and rail), assembly (VAB internal dimensions and door size), roll-out limits, and launch pad size.

Jaap, John↗

Contingency Operations of Americas Next Moon Rocket, Ares V

America has begun the development of a new space vehicle system which will enable humans to return to the moon and reach even farther destinations. The system is called Constellation: it has 2 earth-launch vehicles, Ares I and Ares V; a crew module, Orion; and a lander, Altair with descent and ascent stages. Ares V will launch an Earth Departure Stage (EDS) and Altair into low earth orbit. Ares I will launch the Orion crew module into low earth orbit where it will rendezvous and dock with the Altair and EDS "stack". After rendezvous, the stack will contain four complete rocket systems, each capable of independent operations. Of course this multiplicity of vehicles provides a multiplicity of opportunities for off-nominal behavior and multiple mitigation options for each. Contingency operations are complicated by the issues of crew safety and the possibility of debris from the very large components impacting the ground. This paper examines contingency operations of the EDS in low earth orbit, during the boost to translunar orbit, and after the translunar boost. Contingency operations under these conditions have not been a consideration since the Apollo era and analysis of the possible contingencies and mitigations will take some time to evolve. Since the vehicle has not been designed, much less built, it is not possible to evaluate contingencies from a root-cause basis or from a probability basis; rather they are discussed at an effects level (such as the reaction control system is consuming propellant at a high rate). Mitigations for the contingencies are based on the severity of the off-nominal condition, the time of occurrence, recovery options, options for alternate missions, crew safety, evaluation of the condition (forensics) and future prevention. Some proposed mitigations reflect innovation in thinking and make use of the multiplicity of on-orbit resources including the crew; example: Orion could do a "fly around" to allow the crew to determine the condition and cause of a partially separated payload shroud. Other mitigations are really alternate missions; example, an engine out on during ascent resulted in insufficient propellant for the lunar mission, but the on-orbit vehicle stack is otherwise perfect and can pursue an alternate mission, such as a high ballistic trajectory to test the high-speed atmospheric reentry of Orion. Evaluation and presentation of contingency operations at this early stage of the development of the Ares V rocket will improve the design of the vehicle and lay the groundwork for the exhaustive contingency planning which must be done after the vehicle is built as preparations for operations.

Jaap, John↗

Lessons Learned in Building the Ares Projects

Since being established in 2005, the Ares Projects at Marshall Space Flight Center have been making steady progress designing, building, testing, and flying the next generation of exploration launch vehicles. Ares is committed to rebuilding crucial capabilities from the Apollo era that made the first human flights to the Moon possible, as well as incorporating the latest in computer technology and changes in management philosophy. One example of an Apollo-era practice has been giving NASA overall authority over vehicle integration activities, giving civil service engineers hands-on experience in developing rocket hardware. This knowledge and experience help make the agency a "smart buyer" of products and services. More modern practices have been added to the management tool belt to improve efficiency, cost effectiveness, and institutional knowledge, including knowledge management/capture to gain better insight into design and decision making; earned value management, where Ares won a NASA award for its practice and implementation; designing for operability; and Lean Six Sigma applications to identify and eliminate wasted time and effort. While it is important to learn technical lessons like how to fly and control unique rockets like the Ares I-X flight test vehicle, the Ares management team also has been learning important lessons about how to manage large, long-term projects.

Sumrall, John Phil↗

2010 JPC Abstract: Ares I First Stage Propulsion System Status

In November 2005, NASA created the Constellation Program to develop an entirely new fleet of spacecraft to include the Ares I Crew Launch Vehicle and Ares V Cargo Launch vehicles. This mission architecture included the Orion capsule (which would be used to transport astronauts to low-Earth orbit and beyond), the Altair lunar lander, and an Earth departure stage. The Ares First Stage Team has made significant progress on the design of a propulsion system to meet the objectives of the Constellation Program. Work on a first stage element propulsion system capable of lofting a new fleet of spacecraft is well underway. To minimize technical risks and development costs, the Solid Rocket Boosters (SRBs) of Shuttle served as a starting point in the design of a new motor that would meet the requirements of those new vehicles. This new propulsive element will provide greater total impulse utilizing a fifth segment to loft a safer, more powerful fleet of space flight vehicles. Performance requirements, basic architecture, and obsolescence issues were all factors in determining the new first stage element design and configuration. Early efforts focused on creating designs that would be capable of supporting the requisite loads and environments. While the motor casings are Shuttle legacy, because of Ares I s unique in-line configuration, the first stage will require entirely new forward structures (forward skirt, forward skirt extension, aeroshell, and frustum) and a modified systems tunnel. The use of composites facilitated a change in the geometry, which in turn afforded the ability to focus strength where it was needed without additional mass. The Ares First Stage rocket motor casting tooling was designed and built to achieve a propellant grain geometry that produces the specific required ballistic profile. The new propellant formulation is a polybutadiene acrylonitrile (PBAN) copolymer, which has been modified to attain the desired burn rate and retain adequate tailoring capability.

Priskos, Alex S.↗

Closed-Loop Simulation Study of the Ares I Upper Stage Thrust Vector Control Subsystem for Nominal and Failure Scenarios

As a replacement to the current Shuttle, the Ares I rocket and Orion crew module are currently under development by the National Aeronautics and Space Administration (NASA). This new launch vehicle is segmented into major elements, one of which is the Upper Stage (US). The US is further broken down into subsystems, one of which is the Thrust Vector Control (TVC) subsystem which gimbals the US rocket nozzle. Nominal and off-nominal simulations for the US TVC subsystem are needed in order to support the development of software used for control systems and diagnostics. In addition, a clear and complete understanding of the effect of off-nominal conditions on the vehicle flight dynamics is desired. To achieve these goals, a simulation of the US TVC subsystem combined with the Ares I vehicle as developed. This closed-loop dynamic model was created using Matlab s Simulink and a modified version of a vehicle simulation, MAVERIC, which is currently used in the Ares I project and was developed by the Marshall Space Flight Center (MSFC). For this report, the effects on the flight trajectory of the Ares I vehicle are investigated after failures are injected into the US TVC subsystem. The comparisons of the off-nominal conditions observed in the US TVC subsystem with those of the Ares I vehicle flight dynamics are of particular interest.

Chicatelli, Amy↗

Ares Launch Vehicle Transonic Buffet Testing and Analysis Techniques

It is necessary to define the launch vehicle buffet loads to ensure that structural components and vehicle subsystems possess adequate strength, stress, and fatigue margins when the vehicle structural dynamic response to buffet forcing functions are considered. In order to obtain these forcing functions, the accepted method is to perform wind-tunnel testing of a rigid model instrumented with hundreds of unsteady pressure transducers designed to measure the buffet environment across the desired frequency range. The buffet wind-tunnel test program for the Ares Crew Launch Vehicle employed 3.5 percent scale rigid models of the Ares I and Ares I-X launch vehicles instrumented with 256 unsteady pressure transducers each. These models were tested at transonic conditions at the Transonic Dynamics Tunnel at NASA Langley Research Center. The ultimate deliverable of the Ares buffet test program are buffet forcing functions (BFFs) derived from integrating the measured fluctuating pressures on the rigid wind-tunnel models. These BFFs are then used as input to a multi-mode structural analysis to determine the vehicle response to buffet and the resulting buffet loads and accelerations. This paper discusses the development of the Ares I and I-X rigid buffet model test programs from the standpoint of model design, instrumentation system design, test implementation, data analysis techniques to yield final products, and presents normalized sectional buffet forcing function root-mean-squared levels.

Piatak, David J.↗

The Ares Projects: Back to the Future

This slide presentation reviews the design considerations for the Ares Launch vehicles. It shows design views of both the Ares I and Ares V launch vehicles. It summarizes the utilization studies of the Ares V. There are also pictures of the first stage and upper stage engine being built, and testing of the upper stage engine. Including views of the test stands for the launch vehciles. There is also a description of the planned Ares I-X test flight.

Cook, Steve↗

Ares I-X Malfunction Turn Range Safety Analysis

Ares I-X was the designation given to the flight test version of the Ares I rocket which was developed by NASA (also known as the Crew Launch Vehicle (CLV) component of the Constellation Program). The Ares I-X flight test vehicle achieved a successful flight test on October 28, 2009, from Pad LC-39B at Kennedy Space Center, Florida (KSC). As part of the flight plan approval for the test vehicle, a range safety malfunction turn analysis was performed to support the risk assessment and vehicle destruct criteria development processes. Several vehicle failure scenarios were identified which could have caused the vehicle trajectory to deviate from its normal flight path. The effects of these failures were evaluated with an Ares I-X 6 degrees-of-freedom (6-DOF) digital simulation, using the Program to Optimize Simulated Trajectories Version II (POST2) simulation tool. The Ares I-X simulation analysis provided output files containing vehicle trajectory state information. These were used by other risk assessment and vehicle debris trajectory simulation tools to determine the risk to personnel and facilities in the vicinity of the launch area at KSC, and to develop the vehicle destruct criteria used by the flight test range safety officer in the event of a flight test anomaly of the vehicle. The simulation analysis approach used for this study is described, including descriptions of the failure modes which were considered and the underlying assumptions and ground rules of the study.

Beaty, J. R.↗

ARES I Upper Stage Subsystems Design and Development

From 2005 through early 2011, NASA conducted concept definition, design, and development of the Ares I launch vehicle. The Ares I was conceived to serve as a crew launch vehicle for beyond-low-Earth-orbit human space exploration missions as part of the Constellation Program Architecture. The vehicle was configured with a single shuttle-derived solid rocket booster first stage and a new liquid oxygen/liquid hydrogen upper stage, propelled by a single, newly developed J-2X engine. The Orion Crew Exploration Vehicle was to be mated to the forward end of the Ares I upper stage through an interface with fairings and a payload adapter. The vehicle design passed a Preliminary Design Review in August 2008, and was nearing the Critical Design Review when efforts were concluded as a result of the Constellation Program s cancellation. At NASA Glenn Research Center, four subsystems were developed for the Ares I upper stage. These were thrust vector control (TVC) for the J-2X, electrical power system (EPS), purge and hazardous gas (P&HG), and development flight instrumentation (DFI). The teams working each of these subsystems achieved 80 percent or greater design completion and extensive development testing. These efforts were extremely successful representing state-of-the-art technology and hardware advances necessary to achieve Ares I reliability, safety, availability, and performance requirements. This paper documents the designs, development test activity, and results.

Frate, David T.↗

Assembly of 5.5-Meter Diameter Developmental Barrel Segments for the Ares I Upper Stage

Full scale assembly welding of Ares I Upper Stage 5.5-Meter diameter cryogenic tank barrel segments has been performed at the Marshall Space Flight Center (MSFC). One full-scale developmental article produced under the Ares 1 Upper Stage project is the Manufacturing Demonstration Article (MDA) Barrel. This presentation will focus on the welded assembly of this barrel section, and associated lessons learned. Among the MDA articles planned on the Ares 1 Program, the Barrel was the first to be completed, primarily because the process of manufacture from piece parts (barrel panels) utilized the most mature friction stir process planned for use on the Ares US program: Conventional fixed pin Friction Stir Welding (FSW). This process is in use on other space launch systems, including the Shuttle s External Tank, the Delta IV common booster core, the Delta II, and the Atlas V rockets. The goals for the MDA Barrel development were several fold: 1) to prove out Marshall Space Flight Center s new Vertical Weld Tool for use in manufacture of cylindrical barrel sections, 2) to serve as a first run for weld qualification to a new weld specification, and 3) to provide a full size cylindrical section for downstream use in precision cleaning and Spray-on Foam Insulation development. The progression leading into the welding of the full size barrel included sub scale panel welding, subscale cylinder welding, a full length confidence weld, and finally, the 3 seamed MDA barrel processing. Lessons learned on this MDA program have been carried forward into the production tooling for the Ares 1 US Program, and in the use of the MSFC VWT in processing other large scale hardware, including two 8.4 meter diameter Shuttle External Tank barrel sections that are currently being used in structural analysis to validate shell buckling models.

Carter, Robert W.↗

Ares V: Application to Solar System Scientific Exploration

The development of the Ares V launch vehicle will provide levels of performance unseen since the days of Apollo. This capability, like the Saturn V before it, is being developed primarily for crewed lunar missions. However, the tremendous jump in performance offered by the Ares V launch system has tremendous potential for the furtherance of robotic solar system exploration missions as well. Preliminary performance assessments indicate that Ares V could deliver 5 times the payload to Mars as compared to the most capable US expendable launch vehicle available today. Beyond Mars, the outer planets offer a number of high-priority investigations with compelling science. Presently, missions to these destinations are only achievable using indirect flights with gravity assist trajectories and, in many cases, suffer from long flight times. An Ares V with an upper stage could capture these missions using direct flights with shorter interplanetary transfer times that would enable extensive in situ investigations and possibly the return of samples to Earth. This paper lays out an estimate of Ares V performance for moderate and high C3 missions, and goes on to discuss a range of revolutionary mission concepts that could be enabled by this significant in-crease in launch capability.

Elliott, John↗

Mars Pathfinder Landing Site Workshop 2: Characteristics of the Ares Vallis Region and Field Trips in the Channeled Scabland, Washington

Mars Pathfinder will place a single lander on the surface of Mars on July 4, 1997, following a December 1996 launch. As a result of the very successful first Mars Pathfinder Landing Site Workshop, the project has selected the Ares Vallis outflow channel in Chryse Planitia as the landing site. This location is where a large catastrophic outflow channel debouches into the northern lowlands. A second workshop and series of field trips, entitled Mars Pathfinder Landing Site Workshop 2: Characteristics of the Ares Vallis Region and Field Trips in the Channeled Scabland, Washington, were held in Spokane and Moses Lake, Washington. The purpose of the workshop was to provide a focus for learning as much as possible about the Ares Vallis region on Mars before landing there. The rationale is that the more that can be learned about the general area prior to landing, the better scientists will be able interpret the observations made by the lander and rover and place them in the proper geologic context. The field trip included overflights and surface investigations of the Channeled Scabland (an Earth analog for the martian catastrophic outflow channels), focusing on areas particularly analogous to Ares Vallis and the landing site. The overflights were essential for placing the enormous erosional and depositional features of the Channeled Scabland into proper three-dimensional context. The field trips were a joint educational outreach activity involving K-12 science educators, Mars Pathfinder scientists and engineers, and interested scientists from the Mars scientific community. Part 1 of the technical report on this workshop includes a description of the Mars Pathfinder mission, abstracts accepted for presentation at the workshop, an introduction to the Channeled Scabland, and field trip guides for the overflight and two field trips. This part, Part 2, includes the program for the workshop, summaries of the workshop technical sessions, a summary of the field trips and ensuing discussions, late abstracts of workshop presentations, reports on the education and public outreach activities carried out by the educators, and a list of the workshop and field trip participants.

Golombek, M. P.↗

Evolution of a Mars Airplane Concept for the ARES Mars Scout Mission

ARES (Aerial Regional-scale Environmental Survey of Mars) is a proposed Mars Scout mission using an airplane to provide high-value science measurements in the areas of atmospheric chemistry, surface geology and mineralogy, and crustal magnetism. The use of an airplane for robotic exploration of Mars has been studied for over 25 years. There are, however, significant challenges associated with getting an airplane to Mars and flying through the thin, carbon dioxide Martian atmosphere. The traditional wisdom for aircraft design does not always apply for this type of vehicle and geometric, aerodynamic, and mission constraints result in a limited feasible design space. The ARES airplane design is the result of a concept exploration and evolution involving a number of trade studies, downselects, and design refinements. Industry, university, and NASA partners initially proposed a number of different concepts, drawing heavily on past Mars airplane design experience. Concept downselects were conducted with qualitative evaluation and high level analyses, focused on the most important parameters for the ARES mission. Following a successful high altitude test flight of the basic configuration, additional design refinement led to the current design. The resulting Mars airplane concept enables the high-value science objectives of the ARES mission to be accomplished while also fulfilling the desire for a simple, low-risk design.

Smith, Stephen C.↗

Simulating the ARES Aircraft in the Mars Environment

NASA Langley proposed the Aerial Regional-scale Environmental Survey (ARES) of Mars science mission in response to the NASA Office of Space Science 2002 Mars Scout Opportunity. The science-driven mission proposal began with trade studies and determined that a rocket powered aircraft was the best suited platform to complete the ARES science objectives. A high fidelity six degree of freedom flight simulation was required to provide credible evidence that the aircraft design fulfilled mission objectives and to support the aircraft design process by providing performance evaluations. The aircraft was initially modeled using the aero, propulsion, and flight control system components of other aircraft models. As the proposed aircraft design evolved, the borrowed components were replaced with new models. This allowed performance evaluations to be performed as the design was maturing. Basic autopilot features were also developed for the ARES aircraft model. Altitude hold and track hold modes allowed different mission scenarios to be evaluated for both science merit and aircraft performance. Platform stability and data rate requirements were identified for each of the instruments and the aircraft performance was evaluated against those requirements. The results of the simulation evaluations indicate that the ARES design and mission profiles are sound and meet the science objectives.

Kenney, P. Sean↗

From ESAS to Ares: A Chronology

Throughout my career, I have observed many launch vehicle efforts come and go. Although it may appear on the surface that those were dead-end streets, the knowledge we gained through them actually informs the work in progress. Following the tragic loss of the Space Shuttle Columbia's crew, the administration took the Columbia Accident Investigation Board's findings to heart and united the Agency behind the Vision for Space Exploration, with clear goals and objectives, including fielding a new generation of safe, reliable, and affordable space transportation. The genesis of the Ares I Crew Launch Vehicle and Ares V Cargo Launch Vehicle activities now under way by a nationwide Government and industry team was the confirmation of the current NASA Administrator in April 2005. Shortly thereafter, he commissioned a team of aerospace experts to conduct the Exploration Systems Architecture Study (ESAS), which gave shape to launch vehicles that will empower America's resurgence in scientific discovery through human and robotic space exploration. In October 2005, I was asked to lead this effort, building the team and forming the partnerships that will, in turn, build America's next human-rated space transportation system. In November 2006, the Ares I team began conducting the System Requirements Review milestone, just 1 year after its formation. We are gaining momentum toward the first test flight of the integrated vehicle system in 2009, just a few short years away. The Agency is now poised to deliver on the commitment this nation has made to advance our interests in space. In its inaugural year, the Ares team has conducted the first human-rated launch vehicle major milestone in over 30 years. Using the Exploration Systems Architecture Study recommendations as a starting point, the vehicle designs have been evolved to best meet customer and stakeholder requirements to fulfill the strategic goals outlined in the Vision for Space Exploration.

Cook, Stephen A.↗

Ares V: Designing the Heavy Lift Capability to Explore the Moon

NASA's Vision for Exploration requires a safe, efficient, reliable, and versatile launch vehicle capable ofplacing large payloads into Earth orbit for transfer to the Moon and destinations beyond. The Ares V Cargo Launch Vehicle (CaLV) will provide this heavy lift capability. The Ares V launch concept is shown. When it stands on the launch pad at Kennedy Space Center late in the next decade, the Ares V stack will be almost 360 feet fall. As currently envisioned, it will lift 136 metric tons (300,000 pounds) to a 30-by-160 nautical mile orbit at 28.5-degrees inclination, or 55 metric tons (120,000 pounds) to trans-lunar injection. This paper will cover the latest developments in the Ares V project in 2007 and discuss future activities.

Sumrall, John P.↗

J-2X: Progress on the Ares Upper Stage Engine

NASA's Vision for Exploration requires a safe, reliable, affordable upper stage engine to power the Ares I Crew Launch Vehicle (CLV) and the Ares V Cargo Launch Vehicle (CaLV). The J-2X engine epitomizes NASA's philosophy of employing legacy knowledge, heritage hardware, and commonality to carry the next generation of explorers into low-Earth orbit and out into the solar system. As envisioned by the Exploration Systems Architecture Study (ESAS), the reference lunar mission would begin by launching the Ares V into orbit with the Earth Departure Stage (EDS) transporting the Lunar Surface Access Module (LSAM), followed by the Ares I, carrying the Orion Crew Exploration Vehicle, which would rendezvous with the EDS/LSAM before beginning its journey to the Moon.

Byrd, Thomas D.↗

Ares V Launch Capability Enables Future Space Telescopes

NASA's Ares V cargo launch vehicle offers the potential to completely change the paradigm of future space science mission architectures. A major finding of the NASA Advanced Telescope and Observatory Capability Roadmap Study was that current launch vehicle mass and volume constraints severely limit future space science missions. And thus, that significant technology development is required to package increasingly larger collecting apertures into existing launch shrouds. The Ares V greatly relaxes these constraints. For example, while a Delta IV has the ability to launch approximate a 4.5 meter diameter payload with a mass of 13,000 kg to L2, the Ares V is projected to have the ability to launch an 8 to 12 meter diameter payload with a mass of 60,000 kg to L2 and 130,000 kg to Low Earth Orbit. This paper summarizes the Ares V payload launch capability and introduces how it might enable new classes of future space telescopes such as 6 to 8 meter class monolithic primary mirror observatories, 15 meter class segmented telescopes, 6 to 8 meter class x-ray telescopes or high-energy particle calorimeters.

Stahl, H. Philip↗