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NASA NTRSDate not supplied

NASA's Space Launch System Progress Toward the Launch Pad

NASA’s Space Launch System (SLS) took a substantial step toward the launch site in2020 with the move of the Artemis I core stage from the manufacturing site to the test stand as the program plans for a 2021 launch. (Fig. 1) SLS is NASA’s evolvable super-heavy-lift launch vehicle to support deep space exploration. It is based on evolutionary improvement to existing proven propulsion systems. Its twin solid rocket boosters employ a five-segment motor based on the four-segment space shuttle motor. Its four RS-25 main engines will operate at thrust levels higher than those in the space shuttle program. The core stage is anew design that will support propellant tanks for the engines and serve as the attach point for the boosters. Modern streamlined manufacturing processes and materials have been incorporated into the initial configuration with planned onramps for improved performance and/or affordability in subsequent versions. The primary role of SLS is to anchor the transportation for NASA’s Artemis Program to return humans to the Moon and build on the exploration that began during the Apollo Program. This paper will discuss progress to date for the SLS Program and look ahead to important milestones in 2020 and beyond.

John H Honeycutt↗
NASA NTRSDate not supplied

Space Launch System Payload Stage Capability for Ultra-High Characteristic Energy Missions

The Space Launch System (SLS) vehicle is NASA’s cornerstone capability for a new era of human and robotic exploration of deep space. The unrivalled performance of SLS provides the capability to launch the first woman and next man to walk on the lunar surface and to support development of a sustained human presence in cislunar space, and ultimately human missions to Mars. As an evolvable capability with unique launch performance, the opportunities enabled by SLS also include game-changing benefits for science missions, including probes to the outer solar system and beyond. For the last two years, the SLS Program has worked with the Interstellar Probe team at the Johns Hopkins University Applied Physics Laboratory(APL) to provide data that describe how SLS could support a mission that would break through the boundary of the heliosphere and into pristine interstellar space only a decade after launch, enabling earlier science return and greatly increasing spacecraft life in the interstellar medium. In record-breaking time, the ISP as launched on SLS may answer questions raised by the extended mission of NASA’s Voyager spacecraft. While SLS and its efficient Exploration Upper Stage (EUS) offer benefits for exploration of the outer planets, adding one or more additional stages to this architecture makes it even more capable for missions beyond our solar system, offering more realistically appealing flight times that would allow the mission scientists to reap the rewards of exploration. During the time the SLS Program has been working with the Interstellar Probe team, it has identified an expedited path to the Block 2 capability planned for the Interstellar Probe mission, and further matured performance numbers for diverse multi-stage configurations using a combination of commercially available liquid hydrogen (LH2)/liquid oxygen (LOX) upper stages and solid motor kick stages. That work has demonstrated the SLS payload stage capability provides significant benefits and opens trade space for multiple missions in consideration during planning for the next Planetary Science and Astrobiology Decadal Survey. This presentation details the significant benefits SLS can provides for very high characteristic (C3) energy missions by coupling the capabilities of SLS to current commercial rocket propulsion stage systems. These capabilities are explored specifically in the context of an Interstellar Probe architecture in which a small, capable science probe, coupled with carefully tailored mission design trajectories, could be used to explore the outer solar system and the interstellar medium. The presentation will also address the operational logistics of integrating such a mission, explaining the options available for “non-standard” SLS payloads, including processing those with radioisotope power generators or additional propulsion stages. An SLS system overview and capabilities will be presented, along with vehicle configuration and orbit performance capability studies, explaining how SLS is enabling for a variety of high-energy science mission profiles, including launching an exploratory probe bound for interstellar space only a decade after launch.

Rob Stough↗
NASA NTRS2019

Evolution and Impact of Saturn V on Space Launch System from a Guidance, Navigation, and Mission Analysis Perspective

The Saturn V launch vehicle represented a jump in capability for heavy lift launch vehicles, enabling the Lunar Orbit Rendezvous approach to planetary exploration employed by the Apollo program 50 years ago. Following Apollo, and the development of the Space Transportation System, the NASA space exploration program shifted focus from lunar exploration to long-term, sustained, re-usable access to Low Earth Orbit. With the recent focus of NASA on the Artemis program and continued exploration of cislunar space as a precursor to Martian exploration, the shift has swung back to heavy lift capability. To meet this need, NASA has developed the Space Launch System. While the vehicle is a new design, it is heavily influenced by the engineering solutions and approach used on the Saturn V while taking advantage of the state of the art of launch vehicle design. The approach to abort, for example, shares many familiarities with the triggers and concept of operations used on Saturn V. Analysis approaches to dispersed trajectory performance are also very similar, but advances in computing technology have enabled a much more expanded set of inputs that can be modelled and assessed in a rapid manner. Additionally, guided flight algorithms share similar first principles but have expanded to include day of launch wind information. Trajectory optimization has also advanced significantly due to the availability of computing resources, but similar maneuvers and profiles are flown across both vehicles. Also, while the approach of onboard inertial navigation has been maintained between the two programs, the shift from platform to strapdown systems enables reduced complexity in the system design while maintaining required performance. As described, the Space Launch System is the evolution of NASA launch vehicle designs, owing a large heritage to the Saturn vehicle program and incorporating advances in propulsion systems, avionics, computing, and sensor technology over the past 50 years.

Ahmad, Naeem↗
NASA NTRS2015

A Vehicle Management End-to-End Testing and Analysis Platform for Validation of Mission and Fault Management Algorithms to Reduce Risk for NASAs Space Launch System

The engineering development of the National Aeronautics and Space Administration's (NASA) new Space Launch System (SLS) requires cross discipline teams with extensive knowledge of launch vehicle subsystems, information theory, and autonomous algorithms dealing with all operations from pre-launch through on orbit operations. The nominal and off-nominal characteristics of SLS's elements and subsystems must be understood and matched with the autonomous algorithm monitoring and mitigation capabilities for accurate control and response to abnormal conditions throughout all vehicle mission flight phases, including precipitating safing actions and crew aborts. This presents a large and complex systems engineering challenge, which is being addressed in part by focusing on the specific subsystems involved in the handling of off-nominal mission and fault tolerance with response management. Using traditional model-based system and software engineering design principles from the Unified Modeling Language (UML) and Systems Modeling Language (SysML), the Mission and Fault Management (M&FM) algorithms for the vehicle are crafted and vetted in Integrated Development Teams (IDTs) composed of multiple development disciplines such as Systems Engineering (SE), Flight Software (FSW), Safety and Mission Assurance (S&MA) and the major subsystems and vehicle elements such as Main Propulsion Systems (MPS), boosters, avionics, Guidance, Navigation, and Control (GNC), Thrust Vector Control (TVC), and liquid engines. These model-based algorithms and their development lifecycle from inception through FSW certification are an important focus of SLS's development effort to further ensure reliable detection and response to off-nominal vehicle states during all phases of vehicle operation from pre-launch through end of flight. To test and validate these M&FM algorithms a dedicated test-bed was developed for full Vehicle Management End-to-End Testing (VMET). For addressing fault management (FM) early in the development lifecycle for the SLS program, NASA formed the M&FM team as part of the Integrated Systems Health Management and Automation Branch under the Spacecraft Vehicle Systems Department at the Marshall Space Flight Center (MSFC). To support the development of the FM algorithms, the VMET developed by the M&FM team provides the ability to integrate the algorithms, perform test cases, and integrate vendor-supplied physics-based launch vehicle (LV) subsystem models. Additionally, the team has developed processes for implementing and validating the M&FM algorithms for concept validation and risk reduction. The flexibility of the VMET capabilities enables thorough testing of the M&FM algorithms by providing configurable suites of both nominal and off-nominal test cases to validate the developed algorithms utilizing actual subsystem models such as MPS, GNC, and others. One of the principal functions of VMET is to validate the M&FM algorithms and substantiate them with performance baselines for each of the target vehicle subsystems in an independent platform exterior to the flight software test and validation processes. In any software development process there is inherent risk in the interpretation and implementation of concepts from requirements and test cases into flight software compounded with potential human errors throughout the development and regression testing lifecycle. Risk reduction is addressed by the M&FM group but in particular by the Analysis Team working with other organizations such as S&MA, Structures and Environments, GNC, Orion, Crew Office, Flight Operations, and Ground Operations by assessing performance of the M&FM algorithms in terms of their ability to reduce Loss of Mission (LOM) and Loss of Crew (LOC) probabilities. In addition, through state machine and diagnostic modeling, analysis efforts investigate a broader suite of failure effects and associated detection and responses to be tested in VMET to ensure reliable failure detection, and confirm responses do not create additional risks or cause undesired states through interactive dynamic effects with other algorithms and systems. VMET further contributes to risk reduction by prototyping and exercising the M&FM algorithms early in their implementation and without any inherent hindrances such as meeting FSW processor scheduling constraints due to their target platform - the ARINC 6535-partitioned Operating System, resource limitations, and other factors related to integration with other subsystems not directly involved with M&FM such as telemetry packing and processing. The baseline plan for use of VMET encompasses testing the original M&FM algorithms coded in the same C++ language and state machine architectural concepts as that used by FSW. This enables the development of performance standards and test cases to characterize the M&FM algorithms and sets a benchmark from which to measure their effectiveness and performance in the exterior FSW development and test processes. This paper is outlined in a systematic fashion analogous to a lifecycle process flow for engineering development of algorithms into software and testing. Section I describes the NASA SLS M&FM context, presenting the current infrastructure, leading principles, methods, and participants. Section II defines the testing philosophy of the M&FM algorithms as related to VMET followed by section III, which presents the modeling methods of the algorithms to be tested and validated in VMET. Its details are then further presented in section IV followed by Section V presenting integration, test status, and state analysis. Finally, section VI addresses the summary and forward directions followed by the appendices presenting relevant information on terminology and documentation.

Trevino, Luis↗
NASA NTRSDate not supplied

NASA’s Space Launch System: New Launch Capability for Artemis Lunar and Deep Space Science Missions

With stacking and integration of the initial Block 1 Space Launch System (SLS) expected to begin in 2020, NASA’s powerful new launch vehicle is ready to take center stage in the agency’s Artemis program to return astronauts to the Moon. Combining the highest launch thrust and largest payload capacity ever developed, SLS also enables a new generation of high-C3 science missions to destinations such as the gas and ice giants, the Kuiper Belt, and even beyond the solar system. Block 1 is only the beginning, as the vehicle has a planned evolution path to progressively more powerful variants. In addition to these block upgrades providing increased lift capability, the vehicle can be configured to fly in crew configuration with the Orion spacecraft or in cargo configuration with payload fairings for launching science mission or large infrastructure, providing a flexible launch option. For Artemis I, the first SLS flight, the Block 1 vehicle in the crew configuration will send an uncrewed Orion spacecraft to lunar orbit for a thorough systems checkout before the crewed Artemis II flight. The Block 1 vehicle uses a proven propulsion system consisting of solid rocket boosters and RS-25 engines to lift more than 27 metric tons [t] to trans-lunar injection (TLI). In its cargo configuration, Block 1 can be fitted with a 5 m payload fairing. The second variant, Block 1B, uses a more powerful upper stage to increase payload mass to TLI to 38-42 t, depending on crew or cargo configuration. In the crew configuration, a co-manifested payload of up to 10 t can ride along in the Universal Stage Adapter (USA), which has as much volume for payloads as a 5 m-class payload fairing. The Block 2 evolved variant will lift 43-46 t to TLI, depending on crew or cargo configuration. The Block 1B and Block 2 vehicles can be outfitted with an 8.4 m-diameter payload fairing, available in 19.1 m and 27.4 m lengths, providing unprecedented volume for payloads. Larger-diameter 10 m fairings may also be an option in the future on the Block 2 vehicle. The unrivalled mass, volume and high-energy launches of SLS can provide significant mission flexibility for payloads and/or additional upper stages to open trade space for a new generation of exploration missions. SLS was designed to meet requirements for launching large-volume infrastructure as outlined in numerous studies of missions to cislunar space or Mars. Mission concept studies from the science community also point toward new possibilities enabled by SLS. Probes with more robust science packages can be sent to the gas giants. Dual spacecraft can be manifested for missions to Uranus and Neptune. Additional third or fourth payload stages can be encapsulated in the payload fairings to achieve missions to the Kuiper Belt or beyond. In addition, the large volume can be used to design and deploy wide-aperture mirrors on future space telescopes and to enable nuclear-thermal propulsion missions. At AIAA Ascend, the SLS Program will provide technical information on vehicle capabilities as well as descriptions of ongoing discussions with mission planners for utilizing the vehicle for an array of deep space missions.

Stephen Creech↗
NASA NTRSDate not supplied

Space Launch System: Core Stage Thrust Vector Control Systems Engineering Challenges in Reusing Heritage Hardware

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Core Auxiliary Power Unit (CAPU) is derived from the Orbiter Auxiliary Power Unit (APU). The Orbiter and Solid Rocket Booster APU turbines are powered by hot gas produced by catalyzed hydrazine decomposition. On the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. While direct reuse or slight modification of existing hardware may seem to be a triple-win for a program in cost, schedule, and technical risk mitigation, those benefits can only be realized when its degree of application in a new system is carefully and thoughtfully managed. The heritage hardware reuse should be prescribed within the heritage design capability and reuse environments must lie within the envelope of heritage qualification testing. Despite the significant test and flight experience of the Shuttle heritage hardware components, successful integration with the newly designed CS TVC components and incorporation into the stage design proved to be a challenge which required re-qualification of the heritage hardware as well as thorough integrated testing to support flight certification. Examples of the challenges that were overcome include: re-qualifying heritage hardware to survive new shock and vibration environments, certifying performance of extensively modified heritage hardware, regenerating design insight due to lack of available heritage vendor data, showing compliance to modern structural design standards, translation of heritage requirements for analog avionics to modern digital avionics, and interfacing heritage mechanical hardware with newly designed avionics. This paper is the second installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. This paper will discuss several engineering challenges encountered during the development process for SLS CS TVC and how they were successfully overcome to reach flight readiness.

Thrust Vector Control↗
NASA NTRS2012

SKYLAB II - Making a Deep Space Habitat from a Space Launch System Propellant Tank

Called a "House in Space," Skylab was an innovative program that used a converted Saturn V launch vehicle propellant tank as a space station habitat. It was launched in 1973 fully equipped with provisions for three separate missions of three astronauts each. The size and lift capability of the Saturn V enabled a large diameter habitat, solar telescope, multiple docking adaptor, and airlock to be placed on-orbit with a single launch. Today, the envisioned Space Launch System (SLS) offers similar size and lift capabilities that are ideally suited for a Skylab type mission. An envisioned Skylab II mission would employ the same propellant tank concept; however serve a different mission. In this case, the SLS upper stage hydrogen tank is used as a Deep Space Habitat (DSH) for NASA s planned missions to asteroids, Earth-Moon Lagrangian point and Mars.

Griffin, Brand N.↗
NASA NTRS2018

Closed Loop Guidance Trade Study for Space Launch System Block-1B Vehicle

NASA is currently building the Space Launch System (SLS) Block-1 launch vehicle for the Exploration Mission 1 (EM-1) test flight. The design of the next evolution of SLS, Block-1B, is well underway. The Block-1B vehicle is more capable overall than Block-1; however, the relatively low thrust-to-weight ratio of the Exploration Upper Stage (EUS) presents a challenge to the Powered Explicit Guidance (PEG) algorithm used by Block-1. To handle the long burn durations (on the order of 1000 seconds) of EUS missions, two algorithms were examined. An alternative algorithm, OPGUID, was introduced, while modifications were made to PEG. A trade study was conducted to select the guidance algorithm for future SLS vehicles. The chosen algorithm needs to support a wide variety of mission operations: ascent burns to LEO, apogee raise burns, trans-lunar injection burns, hyperbolic Earth departure burns, and contingency disposal burns using the Reaction Control System (RCS). Additionally, the algorithm must be able to respond to a single engine failure scenario. Each algorithm was scored based on pre-selected criteria, including insertion accuracy, algorithmic complexity and robustness, extensibility for potential future missions, and flight heritage. Monte Carlo analysis was used to select the final algorithm. This paper covers the design criteria, approach, and results of this trade study, showing impacts and considerations when adapting launch vehicle guidance algorithms to a broader breadth of in-space operations.

Von der Porten, Paul↗
NASA NTRS2020

Unstructured Grid Development for the Space Launch System Liftoff and Transition Lineloads Computational Analysis

Production of aerodynamic lineloads databases for the Space Launch System (SLS) vehicle at Liftoff and Transition (LOT) conditions has required the development of a Computational Fluid Dynamics (CFD) workflow capable of producing high-quality solutions for this unique phase of flight. Aerodynamic considerations included a wide range of flow angles (from 0°up to 90°total angle of attack), resulting leeside separation, and interaction effects between the three bodies of the integrated SLS vehicle, as well as the nearby launch tower. Computational mesh development for similar problems at the NASA Langley Research Center (such as for the Constellation/Ares launch vehicles) has primarily relied on in-house tools such as VGRID/POSTGRID, with grids designed for NASA-developed and maintained flow solvers such as USM3D and FUN3D. The workflow for such problems has evolved over the development of the various SLS configurations to incorporate new tools such as the Heldenpatch/Heldenmesh grid generator (Helden Aerospace) and CREATE-AV Kestrel (US Department of Defense) flow solver. This paper describes efforts to benchmark a grid generation approach for LOT problems using Heldenpatch/Heldenmesh and Kestrel, verified against prior best practices from VGRID/POSTGRID. Parameters studied include surface grid density, first-layer viscous cell height, and volume grid growth rate parameters. Resulting solutions are compared based on total force and moment values, sectional line loads, and surface pressures, all validated against existing wind tunnel aerodynamic databases where available for the SLS Block 1B Cargo configuration.

Space launch systems↗
NASA NTRS2015

NASA's Space Launch System: An Evolving Capability for Exploration

Designed to enable human space exploration missions, including eventually landings on Mars, NASA's Space Launch System (SLS) represents a unique launch capability with a wide range of utilization opportunities, from delivering habitation systems into the "proving ground" of lunar-vicinity space to enabling high-energy transits through the outer solar system. Substantial progress has been made toward the first launch of the initial configuration of SLS, which will be able to deliver more than 70 metric tons of payload into low Earth orbit (LEO). Preparations are also underway to evolve the vehicle into more powerful configurations, culminating with the capability to deliver more than 130 metric tons to LEO. Even the initial configuration of SLS will be able to deliver greater mass to orbit than any contemporary launch vehicle, and the evolved configuration will have greater performance than the Saturn V rocket that enabled human landings on the moon. SLS will also be able to carry larger payload fairings than any contemporary launch vehicle, and will offer opportunities for co-manifested and secondary payloads. Because of its substantial mass-lift capability, SLS will also offer unrivaled departure energy, enabling mission profiles currently not possible. The basic capabilities of SLS have been driven by studies on the requirements of human deep-space exploration missions, and continue to be validated by maturing analysis of Mars mission options, including the Global Exploration Roadmap. Early collaboration with science teams planning future decadal-class missions have contributed to a greater understanding of the vehicle's potential range of utilization. As SLS draws closer to its first launch, the Program is maturing concepts for future capability upgrades, which could begin being available within a decade. These upgrades, from multiple unique payload accommodations to an upper stage providing more power for inspace propulsion, have ramifications for a variety of missions, from human exploration to robotic science.

Robinson, Kimberly F.↗
NASA NTRSDate not supplied

Space Launch System: SLS Real Time Rollout Monitoring for MPCV

The NASA Space Launch System (SLS) rocket, Orion spacecraft, and Mobile Launcher (ML) are transported to Pad 39B from the Vehicle Assembly Building on a large, tracked vehicle known as the Crawler Transporter (CT). The CT is a holdover from the Apollo and Space Shuttle programs but has been extensively upgraded to accommodate the SLS. The Dynamic Rollout Test (DRT) on March 17, 2022 marked the first full rollout of the SLS and ML. Analysis indicated that loads and vibrations would be well below design limits, but out of an abundance of caution it was decided to monitor the response in real time during the rollout to assure that loads remained within predicted limits. This first rollout was outfitted with extensive test instrumentation such as accelerometers, pressure sensors, and strain gauges. This instrumentation remained in place following the integrated vehicle modal test and was being used for additional Operational Modal Analysis (OMA) during the rollout in addition to the real-time monitoring. This presentation discusses the specific loads and accelerations monitored during the rollout, how and why those responses were chosen, and how the system was implemented. Finally, a post-rollout loads reconstruction is used to assess the process and the analysis tools used for the rollout analysis.

SLS↗
NASA NTRS2014

NASA's Space Launch System Development Status

Development of the National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) heavy lift rocket is shifting from the formulation phase into the implementation phase in 2014, a little more than 3 years after formal program establishment. Current development is focused on delivering a vehicle capable of launching 70 metric tons (t) into low Earth orbit. This "Block 1" configuration will launch the Orion Multi-Purpose Crew Vehicle (MPCV) on its first autonomous flight beyond the Moon and back in December 2017, followed by its first crewed flight in 2021. SLS can evolve to a130t lift capability and serve as a baseline for numerous robotic and human missions ranging from a Mars sample return to delivering the first astronauts to explore another planet. Benefits associated with its unprecedented mass and volume include reduced trip times and simplified payload design. Every SLS element achieved significant, tangible progress over the past year. Among the Program's many accomplishments are: manufacture of core stage test barrels and domes; testing of Solid Rocket Booster development hardware including thrust vector controls and avionics; planning for RS- 25 core stage engine testing; and more than 4,000 wind tunnel runs to refine vehicle configuration, trajectory, and guidance. The Program shipped its first flight hardware - the Multi-Purpose Crew Vehicle Stage Adapter (MSA) - to the United Launch Alliance for integration with the Delta IV heavy rocket that will launch an Orion test article in 2014 from NASA's Kennedy Space Center. The Program successfully completed Preliminary Design Review in 2013 and will complete Key Decision Point C in 2014. NASA has authorized the Program to move forward to Critical Design Review, scheduled for 2015 and a December 2017 first launch. The Program's success to date is due to prudent use of proven technology, infrastructure, and workforce from the Saturn and Space Shuttle programs, a streamlined management approach, and judicious use of new technologies. The result is a safe, affordable, sustainable, and evolutionary path to development of an unprecedented capability for future missions across the solar system. In an environment of economic challenges, the nationwide SLS team continues to meet ambitious budget and schedule targets. This paper will discuss SLS Program and technical accomplishments over the past year and provide a look at the milestones and challenges ahead.

Lyles, Garry↗
NASA NTRSDate not supplied

Comprehensive Test Program of NASA's Space Launch System Rocket Leads to Successful Artemis Mission

NASA’s SLS (Space Launch System) rocket had a successful first launch on Nov. 16, 2022, sending an uncrewed Orion spacecraft to the Moon on the agency’s Artemis I mission. Ten 6U CubeSats were also deployed from SLS during the mission. Orbital insertion parameters, including insertion velocity and altitude, were within hundredths and tenths of a percent from predicted values, corroborating data collected from the individual elements that showed similar performance accuracy. While launch remains the main test – and Artemis I was a true test flight – to collect data, confirm and refine computer models, and validate hardware test data, multiple test programs led up to the first flight and enabled the historic launch. Additionally, SLS was designed from the beginning to be a crew-rated launch vehicle, and teams put the astronauts who will fly on it at the forefront of the development process. This paper and presentation will cover the SLS design and development programs that led to the successful Artemis I mission, and which have set the stage to send the first astronauts back to cislunar space since the Apollo 17 crew in 1972.

John Honeycutt↗
NASA NTRS2018

NASA's Space Launch System: Unprecedented Payload Capabilities

As part of a renewed focus on deep space exploration, NASA and its private sector and international partners are building a new super heavy-lift launch vehicle, the Space Launch System (SLS), as well as the new Orion crew vehicle, and upgrading launch facilities at Kennedy Space Center. Progress made on the Block 1 vehicle, as well as its expected performance metrics and fiscal support from the U.S. administration and Congress, have opened up additional manifest possibilities that the Agency continues to evaluate. Offering a combination of power, payload capacity and departure energy unmatched in contemporary boosters, the SLS family of launch vehicles features the world's most-proven propulsion system: solid rocket boosters and RS-25 main engines with a modified existing cryogenic in-space stage. The initial SLS configuration, Block 1, will deliver at least 26 metric tons (t) of payload to trans-lunar injection (TLI). The vehicle's flexible architecture will enable the rocket to evolve over the next decade to meet the most demanding deep space mission requirements. The second configuration, Block 1B, will deliver at least 34 to 40 t to TLI, depending on whether the crewed or cargo variant is selected. Although designed to facilitate human exploration of deep space, the vehicle also provides game-changing benefits for large science payloads and even harnesses excess capacity to provide small satellites with affordable access to deep space. For the first integrated mission of SLS and Orion, launching from Kennedy Space Center in fiscal year 2020, SLS Block 1 will send Orion on a 25.5-day mission to a distant retrograde lunar orbit with the primary objective to test and validate new systems and procedures. That first mission, called Exploration Mission-1 (EM-1), also has 13 6U-class CubeSat payloads manifested. Those payloads, which will carry out a variety of scientific experiments and technology demonstrations, will deploy in several locations along the trajectory after Orion has separated from SLS. Contractors and suppliers have made significant progress since last year manufacturing the Block 1 vehicle for EM-1. The upper stage and adapters are complete as are the four RS-25 engines. All other major components are constructed and being outfitted for flight. In fact, hardware for the second flight is currently being manufactured at locations across the United States. This paper will outline hardware, avionics and testing progress toward the first and second flights of SLS. Manifest opportunities for primary, co-manifested and secondary payloads will be discussed. An in-depth look at payload utilization and integration will be provided, as well as lessons learned from installing a secondary payload deployment system for EM-1.

Creech, Steve↗
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 underway on preparations for the second flight - using an upgraded version of the vehicle - and beyond. Designed to support human missions into deep space, 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 (GSDO) program is transforming Kennedy Space Center (KSC) 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 is 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 (MAF) 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 (ULA) in Decatur, Alabama, prior to being shipped to Florida for flight preparations. Manufacture of the OSA and the Launch Vehicle Stage Adapter (LVSA) took place at the Friction Stir Facility located at Marshall Space Flight Center (MSFC) 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 t to LEO, 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 EUS, 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 NTRS2013

Game Changing: NASA's Space Launch System and Science Mission Design

NASA s Marshall Space Flight Center (MSFC) is directing efforts to build the Space Launch System (SLS), a heavy-lift rocket that will carry the Orion Multi-Purpose Crew Vehicle (MPCV) and other important payloads far beyond Earth orbit (BEO). Its evolvable architecture will allow NASA to begin with Moon fly-bys and then go on to transport humans or robots to distant places such as asteroids and Mars. Designed to simplify spacecraft complexity, the SLS rocket will provide improved mass margins and radiation mitigation, and reduced mission durations. These capabilities offer attractive advantages for ambitious missions such as a Mars sample return, by reducing infrastructure requirements, cost, and schedule. For example, if an evolved expendable launch vehicle (EELV) were used for a proposed mission to investigate the Saturn system, a complicated trajectory would be required - with several gravity-assist planetary fly-bys - to achieve the necessary outbound velocity. The SLS rocket, using significantly higher C3 energies, can more quickly and effectively take the mission directly to its destination, reducing trip time and cost. As this paper will report, the SLS rocket will launch payloads of unprecedented mass and volume, such as "monolithic" telescopes and in-space infrastructure. Thanks to its ability to co-manifest large payloads, it also can accomplish complex missions in fewer launches. Future analyses will include reviews of alternate mission concepts and detailed evaluations of SLS figures of merit, helping the new rocket revolutionize science mission planning and design for years to come.

Creech, Stephen D.↗
NASA NTRS2018

Space Launch System (SLS) Mission Planner's Guide

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

Smith, David Alan↗
NASA NTRS2018

Space Launch System (SLS) Mission Planner’s Guide

The purpose of this Space Launch System (SLS) Mission Planner’s Guide (MPG) is to provide future payload developers/users with sufficient insight to support preliminary SLS mission planning. Consequently, this SLS MPG is not intended to be a payload requirements document; rather, it organizes and details SLS interfaces/accommodations in a manner similar to that of current Expendable Launch Vehicle (ELV) user guides to support early feasibility assessments. Like ELV programs, specific payload requirements will be defined in unique documentation once manifested to fly on SLS. SLS users requiring additional mission planning information or more detailed technical interchange concerning specific SLS accommodations should contact the SLS Spacecraft/Payload Integration and Evolution (SPIE) office.

Smith, David Alan↗