Wings In Orbit

Scientific and Engineering

Legacies of the Space Shuttle

1971-2010

Foreword: John Young

Robert Crippen

Executive Editor: Wayne Hale

Editor in Chief: Helen Lane

Coeditors: Gail Chapline

Kamlesh Lulla

National Aeronautics and Space Administration

ii

COVER PHOTOS

Front: View of Space Shuttle Endeavour

(STS-118) docked to the International Space

Station in August 2007.

Back: Launch of Space Shuttle Endeavour

(STS-130) during the early morning hours

en route to the International Space Station

in February 2010.

Spine: A rear view of the Orbiter Discovery

showing the drag chute deployed during the

landing of STS-96 at Kennedy Space Center

in May 1999.

Page iii

To the courageous

men and women who devoted

their lives in pursuit

of excellence in the

Space Shuttle Program.

iv

We were honored and privileged to fly the shuttle’s first orbital flight into space

aboard Columbia on April 12, 1981. It was the first time anyone had crewed a space

launch vehicle that hadn’t been launched unmanned. It also was the first vehicle

to use large solid rockets and the first with wings to reenter the Earth’s atmosphere and

land on a runway. All that made it a great mission for a couple of test pilots.

That first mission proved the vehicle could do the basics for which it had been

designed: to launch, operate on orbit, and reenter the Earth’s atmosphere and land

on a runway. Subsequent flights proved the overall capability of the Space Shuttle.

The program went on to deploy satellites, rendezvous and repair satellites, operate as

a microgravity laboratory, and ultimately build the International Space Station.

It is a fantastic vehicle that combines human operations with a large cargo

capability—a capability that is unlikely to be duplicated in future vehicles anytime

soon. The shuttle has allowed expanding the crew to include non-pilots and women.

It has provided a means to include our international partners with the Canada arm,

the European Spacelab, and eventually the Russians in operation with Mir and

the building of the International Space Station. The station allowed expanding that

international cooperation even further.

The Space Shuttle Program has also served as an inspiration for young people to

study science, technology, engineering, and math, which is so important to the future

of our nation.

The Space Shuttle is an engineering marvel perhaps only exceeded by the station

itself. The shuttle was based on the technology of the 1960s and early 1970s.

It had to overcome significant challenges to make it reusable. Perhaps the greatest

challenges were the main engines and the Thermal Protection System.

The program has seen terrible tragedy in its 3 decades of operation, yet it has also

seen marvelous success. One of the most notable successes is the Hubble Space

Telescope, a program that would have been a failure without the shuttle’s capability

to rendezvous, capture, repair, as well as upgrade. Now Hubble is a shining example

of success admired by people around the world.

As the program comes to a close, it is important to capture the legacy of the shuttle

for future generations. That is what “Wings In Orbit” does for space fans, students,

engineers, and scientists. This book, written by the men and women who made

the program possible, will serve as an excellent reference for building future space

vehicles. We are proud to have played a small part in making it happen.

Foreword

John Young

STS-1 Commander

Robert Crippen

STS-1 Pilot

Page v

“...because I know also life is a shuttle.

I am in haste; go along with me...”

– Shakespeare,

The Merry Wives of Windsor, Act V Scene 1

We, the editors of this book, can relate to this portion of a quote by the English

bard, for our lives have been entwined with the Space Shuttle Program for over

3 decades. It is often said that all grand journeys begin with a small first step.

Our journey to document the scientific and engineering accomplishments of this

magnificent winged vehicle began with an audacious proposal: to capture the

passion of those who devoted their energies to its success while answering the

question “What are the most significant accomplishments?” of the longest-

operating human spaceflight program in our nation’s history. This is intended to

be an honest, accurate, and easily understandable account of the research and

innovation accomplished during the era. We hope you will enjoy this book and

take pride in the nation’s investment in NASA’s Space Shuttle Program.

We are fortunate to be a part of an outstanding team that enabled us to tell this

story. Our gratitude to all members of the Editorial Board who guided us patiently

and willingly through various stages of this undertaking.

Acknowledgments:

We are grateful to all the institutions and people that

worked on the book. (See appendix for complete list.) Each NASA field center

and Headquarters contributed to it, along with many NASA retirees and

industry/academic experts. There are a few who made exceptional contributions.

The following generously provided insights about the Space Shuttle Program:

James Abrahamson, Arnold Aldrich, Stephen Altemus, Kenneth Baldwin,

Baruch Blumberg, Aaron Cohen, Ellen Conners, Robert Crippen, Jeanie Engle,

Jack Fischer, William Gerstenmaier, Milton Heflin, Thomas Holloway,

Jack Kaye, Christopher Kraft, David Leckrone, Robert Lindstrom, William Lucas,

Glynn Lunney, Hans Mark, John Mather, Leonard Nicholson, William Parsons,

Brewster Shaw, Robert Sieck, Bob Thompson, J.R.Thompson, Thomas Utsman,

Edward Weiler, John Young, and Laurence Young.

We also gratefully acknowledge the support of Susan Breeden for technical editing,

Cindy Bush for illustrations, and Perry Jackson for graphic design.

Preface and

Acknowledgments

vi

Table of Contents

iii

Dedication

iv

Foreword—John Young and Robert Crippen

v

Preface and Acknowledgments

vi

Table of Contents

viii Editorial Board

ix

Poem—Witnessing the Launch of the Shuttle Atlantis

x

Introduction—Charles Bolden

1

Magnificent Flying Machine—

A Cathedral to Technology

11

The Historical Legacy

12 Major Milestones

32 The Accidents: A Nation’s Tragedy, NASA’s Challenge

42 National Security

53

The Space Shuttle and Its Operations

54 The Space Shuttle

74 Processing the Shuttle for Flight

94 Flight Operations

110 Extravehicular Activity Operations and Advancements

130 Shuttle Builds the International Space Station

157

Engineering Innovations

158 Propulsion

182 Thermal Protection Systems

200 Materials and Manufacturing

226 Aerodynamics and Flight Dynamics

242 Avionics, Navigation, and Instrumentation

256 Software

270 Structural Design

286 Robotics and Automation

302 Systems Engineering for Life Cycle

of Complex Systems

Page vii

319

Major Scientific Discoveries

320 The Space Shuttle and Great Observatories

344 Atmospheric Observations

and Earth Imaging

360 Mapping the Earth: Radars and Topography

370 Astronaut Health and Performance

408 The Space Shuttle: A Platform That Expanded

the Frontiers of Biology

420 Microgravity Research in the Space Shuttle Era

444 Space Environments

459

Social, Cultural, and Educational Legacies

460 NASA Reflects America’s Changing Opportunities;

NASA Impacts US Culture

470 Education: Inspiring Students as Only NASA Can

485

Industries and Spin-offs

497

The Shuttle Continuum, Role of Human Spaceflight

499 President George H.W. Bush

500 Pam Leestma and Neme Alperstein

Elementary School Teachers

502 Norman Augustine

Former President and CEO of Lockheed Martin Corporation

504 John Logsdon

Former Director of Space Policy Institute, Georgetown University

506 Canadian Space Agency

509 General John Dailey

Director of Smithsonian National Air and Space Museum

510 Leah Jamieson

John A. Edwardson Dean of the College of Engineering,

Purdue University

512 Michael Griffin

Former NASA Administrator

517

Appendix

518 Flight Information

530 Program Managers/Acknowledgments

531 Selected Readings

535 Acronyms

536 Contributors’ Biographies

542 Index

viii

Wayne Hale

Chair

Iwan Alexander

Frank Benz

Steven Cash

Robert Crippen

Steven Dick

Michael Duncan

Diane Evans

Steven Hawley

Milton Heflin

David Leckrone

James Owen

Robert Sieck

Michael Wetmore

John Young

Editorial Board

Page ix

Witnessing the Launch of

the Shuttle Atlantis

Howard Nemerov

Poet Laureate of the United States

1963-1964 and 1988-1990

So much of life in the world is waiting, that

This day was no exception, so we waited

All morning long and into the afternoon.

I spent some of the time remembering

Dante, who did the voyage in the mind

Alone, with no more nor heavier machinery

Than the ghost of a girl giving him guidance;

And wondered if much was lost to gain all this

New world of engine and energy, where dream

Translates into deed. But when the thing went up

It was indeed impressive, as if hell

Itself opened to send its emissary

In search of heaven or “the unpeopled world”

(thus Dante of doomed Ulysses) “behind the sun.”

So much of life in the world is memory

That the moment of the happening itself—

So much with noise and smoke and rising clear

To vanish at the limit of our vision

Into the light blue light of afternoon—

Appeared no more, against the void in aim,

Than the flare of a match in sunlight, quickly snuffed.

What yet may come of this? We cannot know.

Great things are promised, as the promised land

Promised to Moses that he would not see

But a distant sight of, though the children would.

The world is made of pictures of the world,

And the pictures change the world into another world

We cannot know, as we knew not this one.

© Howard Nemerov. Reproduced with permission of the copyright owner. Al rights reserved.

x

It is an honor to be invited to write the introduction for this tribute to the Space Shuttle,

yet the invitation presents quite an emotional challenge. In many ways, I lament the

coming of the end of a great era in human spaceflight. The shuttle has been a crown

jewel in NASA’s human spaceflight program for over 3 decades. This spectacular flying

machine has served as a symbol of our nation’s prowess in science and technology

as well as a demonstration of our “can-do” attitude. As we face the fleet’s retirement,

it is appropriate to reflect on its accomplishments and celebrate its contributions.

The Space Shuttle Program was a major leap forward in our quest for space exploration.

It prepared us for our next steps with a fully operational International Space Station and

has set the stage for journeys to deep-space destinations such as asteroids and, eventually,

Mars. Our desire to explore more of our solar system is ambitious and risky, but its

rewards for all humanity are worth the risks. We, as a nation and a global community,

are on the threshold of taking an even greater leap toward that goal.

All the dedicated professionals who worked in the Space Shuttle team—NASA civil

servants and contractors alike—deserve to be proud of their accomplishments in

spite of the constant presence of skeptics and critics and the demoralizing losses of

Challenger (1986) and Columbia (2003) and their dedicated crews. Some of these

scientists and engineers contributed to a large portion of this book. Their passion and

enthusiasm is evident throughout the pages, and their words will take you on a journey

filled with challenges and triumphs. In my view, this is a truly authentic account by

people who were part of the teams that worked tirelessly to make the program

successful. They have been the heart, mind, spirit, and very soul that brought these

amazing flying machines to life.

Unlike any engineering challenge before, the Space Shuttle launched as a rocket, served

as an orbital workstation and space habitat, and landed as a glider. The American

engineering that produced the shuttle was innovative for its time, providing capabilities

beyond our expectations in all disciplines related to the process of launching, working

in space, and returning to Earth. We learned with every succeeding flight how to operate

more efficiently and effectively in space, and this knowledge will translate to all future

space vehicles and the ability of their crews to live and work in space.

The Space Shuttle was a workhorse for space operations. Satellite launching, repair,

and retrieval provided the satellite industry with important capabilities. The Department

of Defense, national security organizations, and commercial companies used the shuttle

to support their ambitious missions and the resultant accomplishments. Without the

shuttle and its servicing mission crews, the magnificent Hubble Space Telescope

astronomical science discoveries would not have been possible. Laboratories carried

in the payload bay of the shuttles provided opportunities to use microgravity’s attributes

for understanding human health, physical and material sciences, and biology. Shuttle

Introduction

Charles Bolden

Page xi

research advanced our understanding of planet Earth, our own star—the sun—and our

atmosphere and oceans. From orbit aboard the shuttle, astronaut crews collected hundreds

of thousands of Earth observation images and mapped 90% of Earth’s land surface.

During this 30-year program, we changed dramatically as a nation. We witnessed

increased participation of women and minorities, the international community, and the

aerospace industry in science and technology—changes that have greatly benefitted

NASA, our nation, and the world. Thousands of students, from elementary school

through college and graduate programs, participated in shuttle programs. These students

expanded their own horizons—from direct interactions with crew members on orbit,

to student-led payloads, to activities at launch and at their schools—and were inspired to

seek careers that benefit our nation.

International collaboration increased considerably during this era. Canada provided

the robotic arm that helped with satellite repair and served as a mobile crew platform

for performing extravehicular activities during construction of the International Space

Station and upgrades and repairs to Hubble. The European Space Agency provided

a working laboratory to be housed in the payload bay during the period in which the

series of space laboratory missions was flown. Both contributions were technical and

engineering marvels. Japan, along with member nations of the European Space Agency

and Canada, had many successful science and engineering payloads. This international

collaboration thus provided the basis for necessary interactions and cooperation.

My personal change and growth as a Space Shuttle crew member are emblematic of the

valuable contribution to strengthening the global community that operating the shuttle

encouraged and facilitated. I was honored and privileged to close out my astronaut

career as commander of the first Russian-American shuttle mission, STS-60 (1994).

From space, Earth has no geographic boundaries between nations, and the common

dreams of the people of these myriad nations are realizable when we work toward the

common mission of exploring our world from space. The International Space Station,

the completion of which was only possible with the shuttle, further emphasizes the

importance of international cooperation as nations including Russia, Japan, Canada, and

the member nations of the European Space Agency join the United States to ensure that

our quest for ever-increasing knowledge of our universe continues to move forward.

We have all been incredibly blessed to have been a part of the Space Shuttle Program.

The “Remarkable Flying Machine” has been an unqualified success and will

remain forever a testament to the ingenuity, inventiveness, and dedication of the

NASA-contractor team. Enjoy this book. Learn more about the shuttle through the eyes

of those who helped make it happen, and be proud of the human ingenuity that made

this complex space vehicle a timeless icon and an enduring legacy.

Magnificent Flying Machine—A Cathedral to Technology

Page 1

Magnificent

Flying Machine—

A Cathedral

to Technology

Certain physical objects become icons of their time. Popular sentiment

transmutes shape, form, and outline into a mythic embodiment of the era

so that abstracted symbols evoke even the hopes and aspirations of the

day. These icons are instantly recognizable even by the merest suggestion

of their shape: a certain wasp-waisted soft drink bottle epitomizes

America of the 1950s; the outline of a gothic cathedral evokes the

Middle Ages of Europe; the outline of a steam locomotive memorializes

the American expansion westward in the late 19th century; a clipper ship

under full sail idealizes global trade in an earlier part of that century.

America’s Space Shuttle has become such an icon, symbolizing American

ingenuity and leadership at the turn of the 21st century. The outline of

the delta-winged Orbiter has permeated the public consciousness. This

stylized element has been used in myriad illustrations, advertisements,

reports, and video snippets—in short, everywhere. It is a fair question to

ask why the Space Shuttle has achieved such status.

Page 2

Magnificent Flying Machine—A Cathedral to Technology

Magnificent

Flying Machine—

A Cathedral

to Technology

Wayne Hale

The first great age of space exploration

culminated with the historic lunar

landing in July 1969. Following that

achievement, the space policymakers

looked back to the history of aviation as

a model for the future of space travel.

The Space Shuttle was conceived as a

way to exploit the resources of the new

frontier. Using an aviation analogy,

the shuttle would be the Douglas DC-3

of space. That aircraft is generally

considered to be the first commercially

successful air transport. The shuttle was

to be the first commercially successful

space transport. This impossible leap

was not realized, an unrealistic goal

that appears patently obvious in

retrospect, yet it haunts the history of

the shuttle to this day. Much of the

criticism of the shuttle originates from

this overhyped initial concept.

In fact, the perceived relationship

between the history of aviation and the

promise of space travel continues to

motivate space policymakers. In some

ways, the analogy that compares space

with aviation can be very illustrative.

So, if an unrealistic comparison for

the shuttle is the leap from the 1903

Wright Flyer to the DC-3 transport of

1935 in a single technological bound,

what is a more accurate comparison?

If the first crewed spacecraft of 1961—

either Alan Shepard’s Mercury or

Yuri Gagarin’s Vostok—are accurately

the analog of the

Wright brothers’ first

aircraft, the Apollo

spacecraft of 1968

should properly be

compared with

the Wright brothers’

1909 “Model B”—

their first commercial

sale. The “B” was

the product of

6 years of tinkering,

experimentation,

and adjustments, but

were only two major

iterations of aircraft

design. In much the

same way, Apollo

was the technological

inheritor of two

iterations of spacecraft

design in 7 years.

The Space Shuttle

of 1981—coming 20

years after the first

spaceflights—could be compared with

the aircraft of the mid 1920s. In fact,

there is a good analogy in the history of

aviation: the Ford Tri-Motor of 1928.

The Ford Tri-Motor was the leap from

experimental to operational and had the

potential to be economically effective

as well. It was a huge improvement

in aviation—it was revolutionary,

flexible, and capable. The vehicle

carried passengers and the US mail.

Admiral Richard Evelyn Byrd used

the Ford Tri-Motor on his historic

flyover of the North Pole. But the

Ford Tri-Motor was not quite reliable

enough, economical enough, or safe

enough to fire off a successful and

vibrant commercial airline business;

just like the Space Shuttle.

Magnificent Flying Machine—A Cathedral to Technology

Page 3

Lower left: 1903 Wright Flyer; right: Douglas aircraft DC-3 of 1935. Smithsonian National Air and Space Museum,Washington, DC. (photos by Wayne Hale)

Top: 1928 Ford Tri-Motor; above: 1909 Wright

“Model B.” Smithsonian National Air and Space

Museum, Washington,DC.(photos by Wayne Hale)

But here the aviation analogy breaks

down. In aviation history, advances are

made not just because of the passage

of calendar time but because there are

hundreds of different aircraft designs

with thousands of incremental

technology advances tested in flight

between the “B” and the Tri-Motor.

Even so, the aviation equivalent

compression of decades of

technological advance does not do

justice to the huge technological leap

from expendable rockets and capsules

to a reusable, winged, hypersonic,

cargo-carrying spacecraft. This was

accomplished with no intermediate

steps. Viewed from that perspective,

the Space Shuttle is truly a wonder.

No doubt the shuttle is but one step

of many on the road to the stars,

but it was a giant leap indeed.

That is what this book is about: not

what might have been or what was

impossibly promised, but what

was actually achieved and what was

actually delivered. Viewed against this

background, the Space Shuttle was a

tremendous engineering achievement—

a vehicle that enabled nearly routine and

regular access to space for hundreds of

people, and a profoundly vital link in

scientific advancement. The vision of

this book is to take a clear-eyed look at

what the shuttle accomplished and the

shuttle’s legacy to the world.

Superlative Achievements

of the Space Shuttle

For almost half a century, academic

research, study, calculations, and

myriad papers have been written about

the problems and promises of

controlled, winged hypersonic flight

through the atmosphere. The Space

Shuttle was the largest, fastest, winged

hypersonic aircraft in history. Literally

everything else had been a computer

model, a wind tunnel experiment, or

some subscale vehicle launched on

a rocket platform. The shuttle flew at

25 times the speed of sound; regularly.

The next fastest crewed vehicle—the

venerable X-15—flew at its peak at

seven times the speed of sound.

Following the X-15, the next fastest

crewed vehicle was the military SR-71,

which could achieve three times the

speed of sound. Both the X-15 and the

SR-71 were retired years ago. Flight

above about Mach 2 is not practiced

today. If the promise of regular,

commercial hypersonic flight is ever to

come to fruition, the lessons learned

from the shuttle will be an important

foundation. For example, the specifics

of aerodynamic control change

significantly with these extreme speeds.

Prior to the first flight, computations

for the shuttle were found to be

seriously in error when actual postflight

data were reviewed. Variability in

the atmosphere at extreme altitudes

would have gone undiscovered except

for the regular passage of the shuttle

through regions unnavigable any other

way. Serious engineering obstacles

with formidable names—hypersonic

boundary layer transition, for

example—must be understood and

overcome, and cannot be studied in

wind tunnels or computer simulations.

Only by flight tests will real data

help us understand and tame these

dragons of the unknown ocean of

hypersonic flight.

Most authorities agree that getting

back safely from Earth orbit is a more

difficult task than achieving Earth orbit

in the first place. All the tremendous

energy that went into putting the

spacecraft into orbit must be cancelled

out. For any vehicle’s re-entry into

Earth’s atmosphere, this is principally

accomplished by air friction—turning

kinetic energy into heat. Objects

entering the Earth’s atmosphere are

almost always rapidly vaporized by

the friction generated by the enormous

velocity of space travel. Early spacecraft

carried huge and bulky ablative heat

shields, which were good for one use

only. The Space Shuttle Orbiter was

completely reusable, and was covered

with Thermal Protection Systems from

nose to tail. The thermal shock standing

9 mm (0.3 in.) off the front of the wing

leading edge exceeded the temperature

of the visible surface of the sun:

8,000°C (14,000°F). At such an extreme

temperature, metals don’t melt—they

boil. Intense heating went on for

almost half an hour during a normal

deceleration from 8 km (5 miles) per

second to full stop. Don’t forget that

weight was at a premium. A special

carbon fiber cloth impregnated with

carbon resin was molded to an

aerodynamic shape. This was the

Page 4

Magnificent Flying Machine—A Cathedral to Technology

The second X-15 rocket plane (56-6671) is

shown with two external fuel tanks, which were

added during its conversion to the X-15A-2

configuration in the mid 1960s.

so-called reinforced

carbon-carbon on the

wing leading edge and

nose cone. This amazing

composite was only

5 mm (0.2 in.) thick,

but the aluminum

structure of the Orbiter

was completely reliant

on the reinforced

carbon-carbon for

protection. In areas of

the shuttle where slightly

lower peak temperatures

were experienced, the

airframe was covered

with silica-based tiles.

These tiles were mostly

empty space but

provided protection from

temperatures to 1,000°C

(2,000°F). Extraordinarily lightweight

but structurally robust, easily formed to

whatever shape needed, over 24,000

tiles coated the bottom and sides of the

Orbiter. In demonstrations of the tile’s

effectiveness, a technician held one side

of a shuttle tile in a bare hand while

pointing a blowtorch at the opposite

side. These amazing Thermal Protection

Systems—all invented for the shuttle—

brought 110 metric tons (120 tons) of

vehicle, crew, and payload back to Earth

through the inferno that is re-entry.

Nor is the shuttle’s imaginative

navigation system comparable to any

other system flying. The navigation

system kept track of not only the

shuttle’s position during re-entry, but

also the total energy available to the

huge glider. The system managed

energy, distance, altitude, speed, and

even variations in the winds and

weather to deliver the shuttle precisely

to the runway threshold. The logic

contained in the re-entry guidance

software was the hard-won knowledge

from successful landings.

So much for re-entry. All real rocket

scientists know that propulsion is

problem number one for space travel.

The shuttle excelled in both solid- and

liquid-fueled propulsion elements.

The reusable Solid Rocket Booster

(SRB) motors were the largest and most

powerful solid rocket motors ever

flown. Solid rockets are notable for

their high thrust-to-weight ratio

and the SRB motors epitomized that.

Each one developed a thrust of almost

12 meganewtons (3 million pounds) but

weighed only 600,000 kg (1.3 million

pounds) at ignition (with weight

decreasing rapidly after that). This

was the equivalent motive power of

36,000 diesel locomotives that together

would weigh 26 billion kg (57 billion

pounds). The shuttle’s designers were

grounded in aviation in the 1950s and

thought of the SRB motors as extreme

JATO bottles—those small solid

rockets strapped to the side of

overloaded military transports taking

off from short airfields. (JATO is short

for jet-assisted takeoff, where “jet”

is a generic term covering even rocket

engines.) Those small, strap-on solid

rocket motors paled in comparison with

the SRB motors—some JATO bottles

indeed. Within milliseconds of ignition,

the finely tuned combustion processes

inside the SRB motor generated

internal pressure of over 7 million

pascals (1,000 pounds per square inch

[psi]). The thrust was “throttled” by the

shape in which the solid propellant was

cast inside the case. This was critical

because thrust had to be reduced as the

shuttle accelerated through the speed of

maximum aerodynamic pressure. For

the first 50 years of spaceflight, these

reuseable boosters were the largest

solid rockets ever flown.

Magnificent Flying Machine—A Cathedral to Technology

Page 5

This view of the suspended

Orbiter Discovery shows the

underside covered with Thermal

Protection System tiles.

The Solid Rocket Boosters operated in parallel

with the main engines for the first 2 minutes

of flight to provide the additional thrust needed

for the Orbiter to escape the gravitational pull of

the Earth. At an altitude of approximately 45 km

(24 nautical miles), the boosters separated

from the Orbiter/External Tank, descended on

parachutes, and landed in the Atlantic Ocean.

They were recovered by ships, returned to land,

and refurbished for reuse. The boosters also

assisted in guiding the entire vehicle during

initial ascent. Thrust of both boosters was equal

to over 2 million kg (over 5 million pounds).

Development of the liquid-fueled Space

Shuttle Main Engine was considered

an impossible task in the mid 1970s.

Larger liquid-fueled rockets had been

developed—most notably the Saturn V

first-stage engines, the famous F-1

engine that developed three times the

thrust of the shuttle main engines.

But the F-1 engines burned kerosene

rather than hydrogen and their “gas

mileage” was much lower than the

shuttle main engines. In fact, no more

efficient, liquid-fueled rocket engines

have ever been built. Getting to orbit

requires enormous amounts of energy.

The “mpg” rating of these main

engines was unparalleled in the history

of rocket manufacture. The laws of

thermodynamics define the maximum

efficiency of any “heat engine,” whether

it is the gasoline engine that powers an

automobile, or a big power plant that

generates electricity, or a rocket engine.

Different thermodynamic “cycles”

have different possible efficiencies.

Automobile engines operating on the

Otto cycle typically are 15% of the

maximum theoretical efficiency.

The shuttle main engines operating

on the rocket cycle achieved 99.5% of

the maximum theoretical efficiency.

To put the power of the main engines

in everyday terms: if your car engine

developed the same power per pound as

these engines, your automobile would

be powered by something about the size

and weight of a loaf of bread. And it

would cost less than $100.00. More

efficient engines have never been made,

no matter what measure is used:

horsepower to weight, horsepower to

cost. Nor is the efficiency standard

likely to ever be exceeded by any other

chemical rocket.

So far, this has been about the basic

problem in any journey—getting there

and getting back. But the shuttle was a

space truck, a heavy-lift launch vehicle

in the same class as the Saturn V moon

rocket. In fact, over half of all the mass

put in Earth orbit—and that includes

all rockets from all the nations of the

world from 1957 until 2010—was

put there by the shuttle. Think of that.

The shuttle lofted more mass to Earth

orbit than all the Saturn Vs, Saturn Is,

Atlases, Deltas, Protons, Zenits,

and Long Marches, etc., combined.

And what about all the mass brought

safely home from space? Ninety-seven

percent came home with the shuttle.

The Space Shuttle deployed some

of the heaviest-weight upper stages

for interplanetary probes. The largest

geosynchronous satellites were

launched by the shuttle. What a truck.

What a transportation system.

And Science?

How much science was accomplished

by the Space Shuttle? Start with the

study of the stars. What has the shuttle

done for astronomy? It brought us closer

to the heavens. Shuttle had mounted

telescopes operated directly by the crew

to study the heavens. Not only did the

shuttle launch the Compton Gamma

Ray Observatory, the crew saved it by

fixing its main antenna. Astronauts

deployed the orbiting Chandra X-ray

Observatory and the international polar

star probe Ulysses. A series of

astronomy experiments, under the

moniker SPARTAN, studied comets,

the sun, and galactic objects. The Solar

Maximum Satellite enabled the study

of our sun. And the granddaddy of

them all, the Hubble Space Telescope,

often called the most productive

scientific instrument of all time, made

discoveries that have rewritten the

textbooks on astronomy, astrophysics,

and cosmology—all because of shuttle.

Don’t forget planetary science. Not

only has Hubble looked deeply at

most of the planets, but the shuttle also

launched the Magellan radar mapper

Page 6

to Venus and the Galileo mission to

Jupiter and its moons.

In Earth science, two Spacelab

Atmospheric Laboratory for

Applications and Science missions

studied our own atmosphere, the Laser

Geodynamic Satellite sphere monitors

the upper reaches of the atmosphere

and aids in mapping, and three Space

Radar Laboratory missions mapped

virtually the entire land mass of the

Earth to a precision previously

unachievable. The Upper Atmosphere

Research satellite was also launched

from the shuttle, as was the Earth

Radiation Budget Satellite and a host

of smaller nanosatellites that pursued a

variety of Earth-oriented topics. Most of

all, the pictures and observations made

by the shuttle crews using cameras and

other handheld instruments provided

long-term observation of the Earth, its

surface, and its climate.

Satellite launches and repairs were

a highlight of shuttle missions,

starting with the Tracking and Data

Relay Satellites that are the backbone

for communications with all NASA

satellites—Earth resources,

astronomical, and many more.

Communications satellites were

launched early in the shuttle’s career

but were reassigned to expendable

launches for a variety of reasons.

Space repair and recovery of satellites

started with the capture and repair of the

Solar Maximum Satellite in 1984 and

continued with satellite recovery and

repair of two HS-376 communications

satellites in 1985 and the repair of

Syncom-IV that same year. The most

productive satellite repair involved five

repetitive shuttle missions to the Hubble

Space Telescope to upgrade its systems

and instruments on a regular basis.

Biomedical research also was a

hallmark of many shuttle missions.

Not only were there six dedicated

Spacelab missions studying life

sciences, but there were also countless

smaller experiments on the effects of

microgravity (not quite zero gravity)

on various life forms: from microbes

and viruses, through invertebrates and

insects, to mammals, primates, and

finally humans. This research yielded

valuable insight in the workings of the

human body, with ramifications for

general medical care and disease cure

and prevention. The production of

pharmaceuticals in space has been

investigated with mixed success, but

practical production requires lower cost

transportation than the shuttle provided.

Finally, note that nine shuttle flights

specifically looked at materials science

questions, including how to grow

crystals in microgravity, materials

processing of all kinds, lubrication, fluid

mechanics, and combustion dynamics—

all without the presence of gravity.

Magnificent Flying Machine—A Cathedral to Technology

Backdropped by a cloud-covered part of Earth,

Space Shuttle Discovery approaches the

International Space Station during STS-124 (2008)

rendezvous and docking operations.

The second component of the Japan Aerospace

Exploration Agency's Kibo laboratory,

the Japanese Pressurized Module, is visible in

Discovery's cargo bay.

Magnificent Flying Machine—A Cathedral to Technology

Page 7

Laser Geodynamic Satellite dedicated to

high-precision laser ranging. It was launched

on STS-52 (1992).

View from the Space

Shuttle Columbia’s cabin

of the Spacelab science

module, hosting 16 days

of Neurolab research.

(STS-90 [1998] is in

the center.) This picture

clearly depicts the

configuration of the tunnel

that leads from the cabin

to the module in the

center of the cargo bay.

Spacewalks

Of all the spacewalks (known as

extravehicular activities) conducted

in all the spaceflights of the world,

more than three-quarters of them were

based from the Space Shuttle or with

shuttle-carried crew members at the

International Space Station (ISS)

with the shuttle vehicle attached and

supporting. The only “untethered”

spacewalks were executed from the

shuttle. Those crew members were

buoyed by the knowledge that,

should their backpacks fail, the shuttle

could swiftly come to their rescue.

The final and crowning achievement

of the shuttle was to build the ISS.

The shuttle was always considered

only part of the future of space

infrastructure. The construction and

servicing of space stations was one of

the design goals for the shuttle. The

ISS—deserving of a book in its own

right—is the largest space international

engineering project in the history of the

world. The ISS and the Space Shuttle

are two sides of the same coin: the ISS

could not be constructed without the

shuttle, and the shuttle would have lost

a major reason for its existence without

the ISS. In addition to the scientific

accomplishments of the ISS and the

engineering marvel of its construction,

the ISS is important as one of the

shining examples of the power of

international cooperation for the good

of all humanity. The shuttle team

was always international due to the

Canadian contributions of the robot

arm, the international payloads, and

the international spacefarers. But

participation in the construction of the

ISS brought international cooperation to

a new level, and the entire shuttle team

was transformed by that experience.

The Astronauts

In the final analysis, space travel is all

about people. In 133 flights, the Space

Shuttle provided nearly 850 seats to

orbit. Many people have been to orbit

more than once, so the total number

of different people who have flown to

space on all spacecraft (Vostok,

Mercury, Voskhod, Gemini, Soyuz,

Apollo, Shenzhou, and the shuttle)

in the last 50 years is just under 500.

Of that number, over 400 have flown on

the Space Shuttle. Almost three times

as many people flew to space on the

Page 8

shuttle than on all other vehicles from

all countries of the world combined.

If the intent was to transform space

and the opening of the frontier to more

people, the shuttle accomplished this.

Fliers included politicians, officials

from other agencies, scientists of all

types, and teachers. Probably most

telling, these spacefarers represented a

multiplicity of ethnicities, genders, and

citizenships. The shuttle truly became

the people’s spaceship.

Fourteen people died flying on the

shuttle in two accidents. They too

represented the broadest spectrum of

humanity. In 11flights, Apollo lost

no astronauts in space—although

Apollo 13 was a very close call—

and only three astronauts in a ground

accident. Soyuz, like shuttle, had two

fatal in-flight accidents but lost only

four souls due to the smaller carrying

capacity. The early days of aviation

were far bloodier, even though the

altitudes and energies were a fraction

of those of orbital flight.

Magnificent Flying Machine—A Cathedral to Technology

Anchored to a foot restraint on Space Shuttle Atlantis' remote manipulator system robotic arm,

Astronaut John Olivas, STS-117 (2007), moves toward Atlantis' port orbital maneuvering system

pod that was damaged during the shuttle's climb to orbit. During the repair, Olivas pushed the

turned-up portion of the thermal blanket back into position, used a medical stapler to secure

the layers of the blanket, and pinned it in place against adjacent thermal tile.

Space Shuttle Discovery docked to the International Space Station is featured in this image

photographed by one of the STS-119 (2009) crew members during the mission's first scheduled

extravehicular activity.

How Do We Rate the

Space Shuttle?

Did shuttle have the power of thousands

of diesel locomotives? Was it the most

efficient rocket system ever built?

Certainly it was the only winged space

vehicle that flew from orbit as a

hypersonic glider. And it was the only

reusable space vehicle ever built except

for the Soviet Buran (“Snowflake”),

which was built to be reusable but only

flew once. Imitation is the sincerest form

of flattery; the Buran was the greatest

compliment the shuttle ever had.

In the 1940s and early 1950s, the world’s

experimental aircraft flew sequentially

faster and higher.The X-15 even allowed

six people to earn their astronaut wings

for flying above 116,000 m (380,000 ft)

in a parabolic suborbital trajectory. If the

exigencies of the Cold War—the state

of conflict, tension, and competition that

existed between the United States and

the Soviet Union and their respective

allies from the mid 1940s to the early

1990s—had not forced a rapid entry

into space on the top of intercontinental

ballistic missiles, a far different

approach to spaceflight would most

likely have occurred with air-breathing

winged vehicles flying to the top of the

atmosphere and then smaller rocket

stages to orbit. But that buildup

approach didn’t happen. Some

historians think such an approach would

have provided a more sustainable

approach to space than expendable

intercontinental ballistic missile-based

launch systems. Hypersonic flight

continues to be the subject of major

research by the aviation community.

Plans to build winged vehicles that can

take off horizontally and fly all the way

to Earth orbit are still advanced as the

“proper” way to travel into space. Time

will tell if these dreams become reality.

No matter the next steps in space

exploration, the legacy of the Space

Shuttle will be to inspire designers,

planners, and astronauts. Because

building a Space Shuttle was thought

to be impossible, and yet it flew, the

shuttle remains the most remarkable

achievement of its time—a cathedral of

technology and achievement for future

generations to regard with wonder.

Magnificent Flying Machine—A Cathedral to Technology

Page 9

The sun radiates on Space Shuttle Atlantis

as it is positioned to head for space on mission

STS-115 (2006).

Astronaut Joseph Acaba, STS-119 (2009), works the controls of Space Shuttle Discovery’s Shuttle

Robotic Arm on the aft flight deck during Flight Day 1 activities.

Page 10

The Historical Legacy

Page 11

The Historical

Legacy

Major Milestones

The Accidents: A Nation’s

Tragedy, NASA’s Challenge

National Security

Astronauts John Young and Robert Crippen woke early on the morning

of April 12, 1981, for the second attempted launch of the Space Shuttle

Columbia—the first mission of the Space Shuttle Program. Two days

earlier, the launch had been scrubbed due to a computer software error.

Those working in the Shuttle Avionics Integration Laboratory at Johnson

Space Center (JSC) in Houston, Texas, quickly resolved the issue and,

with the problem fixed, the agency scheduled a second try soon after.

Neither crew member expected to launch, however, because so much had

to come together for liftoff to occur.

That morning, they did encounter a serious problem. With fewer than

2 hours until launch, the crew of Space Transportation System (STS)-1

locked the faceplates onto their helmets, only to find that they could not

breathe. To avoid scrubbing the mission, the crew members looked at

the issue and asked Loren Shriver, the astronaut support pilot, to help

them. Finding a problem with the oxygen hose quick disconnect, Shriver

tightened the line with a pair of pliers, and the countdown continued.

At 27 seconds before launch, Crippen realized that this time they were

actually going to fly. His heart raced to 130 beats per minute while

Young’s heart, that of a veteran commander, stayed at a calm 85 beats.

Young later joked, “I was excited too. I just couldn’t get my heart to

beat any faster.” At 7:00 a.m., Columbia launched, making its maiden

voyage into Earth orbit on the 20th anniversary of Yuri Gagarin’s

historic first human flight into space (1961).

The thousands who had traveled to the beaches of Florida’s coastline

to watch the launch were excited to see the United States return to flying

in space. The last American flight was the Apollo-Soyuz Test Project,

which flew in July 1975 and featured three American astronauts and two

cosmonauts who rendezvoused and docked their spacecraft in orbit.

Millions of others who watched the launch of STS-1 from their television

sets were just as elated. America was back in space.

Page 12

The Historical Legacy

Major

Milestones

Jennifer Ross-Nazzal

Dennis Webb

Like their predecessors, Young and

Crippen became heroes for flying this

mission—the boldest test flight in

history. The shuttle was like no other

vehicle that had flown; it was reusable.

Unlike the space capsules of the

previous generation, the shuttle had not

been tested in space. This was the first

test flight of the Columbia and the only

time astronauts had actually flown a

spacecraft on its first flight. The

primary objective was to prove that the

shuttle could safely launch a crew and

then return safely to Earth. Two days

later, the mission ended and the goal

was accomplished when Young landed

the shuttle at Dryden Flight Research

Center on the Edwards Air Force

Base runway in California. The

spacecraft had worked like a “champ”

in orbit—even with the loss of several

tiles during launch. After landing,

Christopher Kraft, director of JSC, said,

“We just became infinitely smarter.”

Design and Development

It would be a mistake to say that the

first flight of Columbia was the start of

the Space Shuttle Program. The idea

of launching a reusable winged vehicle

was not a new concept. Throughout the

1960s, NASA and the Department of

Defense (DoD) studied such concepts.

Advanced Space Shuttle studies began

in 1968 when the Manned Spacecraft

Center—which later became JSC—

and Marshall Space Flight Center in

Huntsville, Alabama, issued a joint

request for proposal for an integral

launch and re-entry vehicle to study

different configurations for a round-trip

vehicle that could reduce costs, increase

safety, and carry payloads of up to

22,680 kg (50,000 pounds). This

marked the beginning of the design

and development of the shuttle.

Four contractors—General Dynamics/

Convair, Lockheed, McDonnell

Douglas, and North American

Rockwell—received 10-month

contracts to study different approaches

for the integral launch and re-entry

vehicle. Experts examined a number

of designs, from fully reusable vehicles

to the use of expendable rockets.

On completion of these studies, NASA

determined that a two-stage, fully

reusable vehicle met its needs and

would pay off in terms of cost savings.

On April 1, 1969, Maxime Faget,

director of engineering and

development at the Manned Spacecraft

Center, asked 20 people to report to

the third floor of a building that most

thought did not have a third floor.

Because of that, many believed it was

an April Fool’s prank but went anyway.

Once there, they spotted a test bay,

which had three floors, and that was

where they met. Faget then walked

through the door with a balsa wood

model of a plane, which he glided

toward the engineers. “We’re going to

build America’s next spacecraft.

And it’s going to launch like a

spacecraft, it’s going to land like a

plane,” he told the team. America had

not yet landed on the moon, but

NASA’s engineers moved ahead with

plans to create a new space vehicle.

As the contractors and civil servants

explored various configurations for

the next generation of spacecraft, the

Space Task Group, appointed by

President Richard Nixon, issued its

report for future space programs. The

committee submitted three options:

the first and most ambitious featured

a manned Mars landing as early as

1983, a lunar and Earth-orbiting

station, and a lunar surface base; the

second supported a mission to Mars

in 1986; and the third deferred the

Mars landing, providing no scheduled

date for its completion. Included in

the committee’s post-Apollo plans

were a Space Shuttle, referred to as

the Space Transportation System, and

a space station, to be developed

simultaneously. Envisioned as less

costly than the Saturn rocket and

Apollo capsules, which were expended

after only one use, the shuttle would

be reusable and, as a result, make

space travel more routine and less

costly. The shuttle would be capable

of carrying passengers, supplies,

satellites, and other equipment—

much as an airplane ferries people

and their luggage—to and from orbit

at least 100 times before being

retired. The system would support

both the civil and military space

programs and be a cheaper way to

launch satellites. Nixon, the Space

Task Group proposals, and NASA cut

the moon and Mars from their plans.

This left only the shuttle and station

for development, which the agency

hoped to develop in parallel.

The Historical Legacy

Page 13

Maxime Faget, director of engineering and

development at the Manned Spacecraft Center

in 1969, holding a balsa wood model of his

concept of the spaceship that would launch on

a rocket and land on a runway.

The decision to build a shuttle was

extremely controversial, even though

NASA presented the vehicle as

economical—a cost-saver for

taxpayers—when compared with the

large outlays for the Apollo Program.

In fact, in 1970 the shuttle was nearly

defeated by Congress, which was

dealing with high inflation, conflict in

Vietnam, spiraling deficits, and an

economic recession. In April 1970,

representatives in the House narrowly

defeated an amendment to eliminate all

funding for the shuttle. A similar

amendment offered in the Senate was

also narrowly defeated. Minnesota

Senator Walter Mondale explained that

the money NASA requested was

simply the “tip of the iceberg.” He

argued that the $110 million requested

for development that year might be

better spent on urban renewal projects,

veterans’ care, or improving the

environment. Political support for the

program was very tenuous, including

poor support from some scientific and

aerospace leaders.

To garner support for the shuttle and

eliminate the possibility of losing the

program, NASA formed a coalition with

the US Air Force and established a joint

space transportation committee to meet

the needs of the two agencies. As an Air

Force spokesman explained, given the

political and economic realities of the

time, “Quite possibly neither NASA nor

the DoD could justify the shuttle system

alone. But together we can make a

strong case.”

The Space Shuttle design that NASA

proposed did not initially meet the

military’s requirements. The military

needed the ability to conduct a polar

orbit with quick return to a military

airfield. This ability demanded the

now-famous delta wings as opposed

to the originally proposed airplane-like

straight wings. The Air Force also

insisted that it needed a larger payload

bay and heavier lift capabilities to

carry and launch reconnaissance

satellites. A smaller payload bay would

require the Air Force to retain their

expendable launch vehicles and chip

away at the argument forwarded by

NASA about the shuttle’s economy and

utilitarian purpose. The result was a

larger vehicle with more cross-range

landing capability.

Though the president and Congress

had not yet approved the shuttle in

1970, NASA awarded preliminary

design contracts to McDonnell Douglas

and North American Rockwell, thus

beginning the second phase of

development. By awarding two contracts

for the country’s next-generation

spacecraft, NASA signaled its decision

to focus on securing support for the

two-stage reusable space plane over the

station, which received little funding

and was essentially shelved until 1984

when President Ronald Reagan directed

the agency to build a space station

within a decade. In fact, when James

Fletcher became NASA’s administrator

in April 1971, he wholeheartedly

supported the shuttle and proclaimed,

“I don’t want to hear any more about a

space station, not while I am here.”

Fletcher was doggedly determined to

see that the federal government funded

the shuttle, so he worked closely with

the Nixon administration to assure the

program received approval. Realizing

that the $10.5 billion price tag for the

development of the fully reusable,

two-stage vehicle was too high, and

facing massive budget cuts from the

Office of Management and Budget, the

administrator had the agency study the

use of expendable rockets to cut the

high cost and determine the significant

cost savings with a partially reusable

spacecraft as opposed to the proposed

totally reusable one. On learning that

use of an expendable External Tank,

which would provide liquid oxygen

and hydrogen fuel for Orbiter engines,

would decrease costs by nearly half,

NASA chose that technology—thereby

making the program more marketable

to Congress and the administration.

Robert Thompson, former Space

Shuttle Program manager, believed that

the decision to use an expendable

External Tank for the Space Shuttle

Main Engines was “perhaps the single

most important configuration decision

made in the Space Shuttle Program,”

resulting in a smaller, lighter shuttle.

“In retrospect,” Thompson explained,

“the basic decision to follow a less

complicated development path at the

future risk of possible higher operating

costs was, in my judgment, a very wise

choice.” This decision was one of the

program’s major milestones, and the

decreased costs for development had

the desired effect.

Presidential Approval

Nixon made the announcement in

support of the Space Shuttle Program

at his Western White House in San

Clemente, California, on January 5,

1972. Believing that the shuttle was a

good investment, he asked the space

agency to stress that the shuttle was not

an expensive toy. The president

highlighted the benefits of the civilian

and military applications and

emphasized the importance of

international cooperation, which

would be ushered in with the program.

Ordinary people from across the

globe, not just American test pilots,

could fly on board the shuttle.

From the start, Nixon envisioned the

shuttle as a truly international program.

Even before the president approved

the program, NASAAdministrator

Thomas Paine, at Nixon’s urging,

approached other nations about

participating. As NASA’s budget

worsened, partnering with other nations

became more appealing to the space

agency. In 1973, Europe agreed to

develop and build the Spacelab, which

Page 14

The Historical Legacy

would be housed in the payload bay of

the Orbiter and serve as an in-flight

space research facility. The Canadians

agreed to build the Shuttle Robotic Arm

in 1975, making the Space Shuttle

Program international in scope.

Having the Nixon administration

support the shuttle was a major hurdle,

but NASA still had to contend with

several members of Congress who

disagreed with the administration’s

decision. In spite of highly vocal

critics, both the House and Senate

voted in favor of NASA’s authorization

bill, committing the United States to

developing the Space Shuttle and,

thereby, marking another milestone

for the program.

To further reduce costs, NASA

decided to use Solid Rocket Boosters,

which were less expensive to build

because they were a proven technology

used by the Air Force in the Minuteman

intercontinental ballistic missile

program. As NASAAdministrator

Fletcher explained, “I think we have

made the right decision at the right

time. And I think it is the right price.”

Solids were less expensive to develop

and cost less than liquid boosters. To

save additional funds, NASA planned

to recover the Solid Rocket Boosters

and refurbish them for future flights.

Contracting out the Work

Two days after NASA selected the

parallel burn Solid Rocket Motor

propellant configuration, the agency

put out a request for proposal for the

development of the Orbiter. Four

companies responded. NASA selected

North American Rockwell, awarding

the company a $2.6 billion contract.

The Orbiter that Rockwell agreed to

build illustrated the impact the Air

Force had on the design. The payload

bay measured 18.3 by 4.6 m (60 by

15 ft), to house the military’s satellites.

The Orbiter also had delta wings and

the ability to deploy a 29,483-kg

(65,000-pound) payload from a

due-east orbit.

As NASA studied alternative concepts

for the program, the agency issued a

request for proposal for the Space

Shuttle Main Engines. In the

summer of 1971, NASA selected

the Rocketdyne Division of Rockwell.

Rocketdyne built the large, liquid fuel

rocket engines used on the NASA

Saturn V (moon rocket). However, the

shuttle engines differed dramatically

from their predecessors. As James

Kingsbury, the director of Science and

Engineering at the Marshall Space

Flight Center, explained, “It was an

unproven technology. Nobody had ever

had a rocket engine that operated at the

pressures and temperatures of that

engine.” Because of the necessary lead

time needed to develop the world’s

first reusable rocket engine, the

selection of the Space Shuttle Main

Engines contractor preceded other

Orbiter decisions, but a contract protest

delayed development by 10 months.

Work on the engines officially began

in April 1972.

Other large companies benefiting

from congressional approval of the

Space Shuttle Program included

International Business Machines,

Martin Marietta, and Thiokol. The

computer giant International Business

Machines would provide five on-board

computers, design and maintain their

software, and support testing in all

ground facilities that used the flight

software and general purpose

computers, including the Shuttle

Avionics Integration Laboratory, the

Shuttle Mission Simulator, and other

facilities. Thiokol received the

contract for the solid rockets, and

NASA selected Martin Marietta to

build the External Tank. Although

Rockwell received the contract for

the Orbiter, the corporation parceled

out work to other rival aerospace

The Historical Legacy

Page 15

companies: Grumman built the wings;

Convair Aerospace agreed to build the

mid-fuselage; and McDonnell Douglas

managed the Orbiter rocket engines,

which maneuvered the vehicle in space.

Rollout tests of the Solid Rocket Boosters. Mobile Launcher Platform number 3, with twin Solid Rocket

Boosters bolted to it, inches along the crawlerway at various speeds up to 1.6 km (1 mile) per hour in

an effort to gather vibration data. The boosters are braced at the top for stability. Data from these tests,

completed September 2004, helped develop maintenance requirements on the transport equipment

and the flight hardware.

Delays and Budget Challenges

Although NASA received approval

for the program in 1972, inflation and

budget cuts continually ate away at

funding throughout the rest of the

decade. Over time, this resulted in slips

in the schedule as the agency had to

make do with effectively fewer dollars

each year and eventually cut or

decrease spending for less-prominent

projects, or postpone them. This also

led to higher total development costs.

Technical problems with the tiles,

Orbiter heat shield, and main engines

also resulted in delays, which caused

development costs to increase. As a

result, NASA kept extending the first

launch date.

The shuttle continued to evolve as

engineers worked to shave weight

from the vehicle to save costs.

In 1974, engineers decided to remove

the shuttle’s air-breathing engines,

which would have allowed a powered

landing of the vehicle. The engines

were to be housed in the payload

bay and would have cost more than

$300 million to design and build, but

Page 16

they took up too much space in the

bay and added substantial complexity

to the design. Thus, the agency decided

to go forward with the idea of an

unpowered landing to glide the Orbiter

and crew safely to a runway.

This decision posed an important

question for engineers: how to bring

the Orbiter from California, where

Rockwell was building it, to the launch

sites in Florida, Vandenberg Air Force

Base, or test sites in Alabama. NASA

considered several options: hanging

the Orbiter from a dirigible; carrying

the vehicle on a ship; or modifying a

Lockheed C-5A or a Boeing 747

to ferry the Orbiter in a piggyback

configuration on the back of the plane.

Eventually, NASA selected the 747

and purchased a used plane from

American Airlines in 1974 to conduct a

series of tests before transforming the

plane into the Shuttle Carrier Aircraft.

Modifications of the 747 began in 1976.

The Space Shuttle Main Engines were the first rocket engines to be reused from one mission to the

next. This picture is of Engine 0526, tested on July 7, 2003. A remote camera captures a close-up view

of a Space Shuttle Main Engine during a test firing at the John C. Stennis Space Center in Hancock

County, Mississippi.

Final Testing

Rollout

On September 17, 1976, Americans

got an initial glimpse of NASA’s first

shuttle, the Enterprise, when a red,

white, and blue tractor pulled the glider

out of the hangar at the Air Force Plant

in Palmdale, California. Enterprise

was not a complete shuttle: it had no

propellant lines and the propulsion

systems (the main engines and orbital

maneuvering pods) were mock-ups.

Originally, NASA intended to name

the vehicle Constitution in honor of the

bicentennial of the United States, but

fans of the television show Star Trek

appealed to NASA and President

Gerald Ford, who eventually relented

and decided to name the shuttle after

Captain Kirk’s spaceship. Speaking

at the unveiling, Fletcher proclaimed

that the debut was “a very proud

moment” for NASA. He emphasized

the dramatic changes brought about

by the program: “Americans and

the people of the world have made the

evolution to man in space—not just

astronauts.” The rollout of Enterprise

marked the beginning of a new era

in spaceflight, one in which all

could participate.

In fact, earlier that summer, the

agency had issued a call for a new

class of astronauts, the first to be

selected since the late 1960s when

nearly all astronauts were test pilots.

A few held advanced degrees in

science and medicine, but none were

women or minorities. Consequently,

NASA emphasized its determination

to select people from these groups

and encouraged women and

minorities to apply.

Approach and Landing Tests

In 1977, Enterprise flew the Approach

and Landing Tests at Dryden Flight

Research Center using Edwards Air

Force Base runways in California.

The program was a series of ground

and flight tests designed to learn

more about the landing characteristics

of the Orbiter and how the mated

shuttle and its carrier operated together.

First, crewless high-speed taxi tests

proved that the Shuttle Carrier Aircraft,

when mated to the Enterprise, could

steer and brake with the Orbiter

perched on top of the airframe. The

pair, then ready for flight, flew five

captive inert flights without astronauts

in February and March, which

qualified the 747 for ferry operations.

Captive-active flights followed in June

and July and featured two-man crews.

The final phase was a series of free

flights (when Enterprise separated

from the Shuttle Carrier Aircraft and

landed at the hands of the two-man

crews) that flew in 1977, from

August to October, and proved the

flightworthiness of the shuttle and

the techniques of unpowered landings.

Most important, the Approach and

Landing Tests Program pointed out

sections of the Orbiter that needed to

be strengthened or made of different

materials to save weight.

The Historical Legacy

Page 17

James Carter

Approach and Landing Tests

Enterprise

Columbia

Main Engine

External Tank

Solid Rocket Booster

First Launch Stack

1

NASA had planned to retrofit Enterprise

as a flight vehicle, but that would have

taken time and been costly. Instead, the

agency selected the other alternative,

which was to have the structural test

article rebuilt for flight. Eventually

called Challenger, this vehicle would

become the second Orbiter to fly in

space after Columbia. Though

Enterprise was no longer slated for

flight, NASA continued to use it for a

number of tests as the program matured.

Getting Ready to Fly

Concurrent with the Approach and

Landing Tests Program, the astronaut

selection board in Houston held

interviews with 208 applicants selected

from more than 8,000 hopefuls. In

1978, the agency announced the first

class of Space Shuttle astronauts.

This announcement was a historic one.

Six women who held PhDs or medical

degrees accepted positions along with

three African American men and a

Japanese American flight test engineer.

After completing 1 year of training,

the group began following the progress

of the shuttle’s subsystems, several of

which had caused the program’s first

launch to slip.

The Space Shuttle Main Engines

were behind schedule and threatened

to delay the first orbital flight, which

was tentatively scheduled for March

1979. Problems plagued the engines

from the beginning. As early as 1974,

the engines ran into trouble as cost

overruns threatened the program

and delays dogged the modification

of facilities in California and the

development of key engine

components. Test failures occurred at

Rocketdyne’s California facility and

the National Space Technology

Laboratory in Mississippi, further

delaying development and testing.

Another pacing item for the program

was the shuttle’s tiles. As Columbia

underwent final assembly in

California, Rockwell employees

began applying the tiles, with the

work to be completed in January 1979.

Their application was much more time

consuming than had been anticipated,

and NASA transferred the ship to

Kennedy Space Center (KSC) in

March, where the task would be

completed in the Orbiter Processing

Facility and later in the Vehicle

Assembly Building. Once in Florida,

mating of the tiles to the shuttle

ramped up. Unfortunately, engineers

found that many of the tiles had to

be strengthened. This resulted in many

of the 30,000 tiles being removed,

tested, and replaced at least once.

The bonding process was so time

consuming that technicians worked

STS-9

Spacelab1

STS-4

First Department of Defense Flight

Lightweight

External Tank

STS-1

First Shuttle

STS-5

First Satellite Deploy

(TDRSS-1)

Orbital Flight Test

STS-41C

Solar Max

STS-61A

D1

STS-51A

PALAPA WESTAR

Retrieve

Atmospheric

Flight Test

Shuttle Mission Icons:

Orbital

Flight Test

Shuttle-Mir

Mission

International Space

Station Mission

Loss of Crew

and Vehicle

Department of Defense

Classied Flight

Satellite Deploy,

Retrieval or Repair

“In the Bay” Science or

Engineering Demonstration

Observatory or Interplanetary

Deploy or Repair

Categories are an approximation as many

missions feature objectives or payloads

that can t in multiple categories. Where

explicit, the primary mission is indicated.

oximation as many

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STS-4

oximation as many

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Orbital Fligh est

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Flight TTest

bital

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“I th B ” S i

Department of Defense

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missions featur

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Categories ar

Challenger

an

First De

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partment of Defense Flight

p

(TDRSS-1)

STS-4

oximation as many

First Satellite Deploy

STS-5

Mission

Shuttle-Mir

Retrieval or Repair

,

Satellite Deploy

Classied Flight

Department of Defense

Deploy or Repair

Observatory or Interplanetary

Discoveryyry

ank

Spacelab1

Lightweight

First Department of Defense Flight

First Satellite Deploy

STS-9

Solar Max

STS-41C

Station Mission

national Space

Inter

ehicle

and V

ew

Loss of Cr

Columbia

Atlantis

Retrieve

*

AR

A WESTTAR

ALAPPA WEST

P LAP

STS-51A

D1

STS-61A

1981

Engineering Demonstration

Deploy or Repair

1982

1983

Ronald Reagan

Mission

Deploy or Repair

1983

1984

Ronald Reagan

Station Mission

ehicle

and V

Atlantis

1985

around the clock, 7 days a week at

KSC to meet the launch deadline.

Aaron Cohen, former manager for

the Space Shuttle Orbiter Project and

JSC director, remembered the stress

and pressure caused by the delays in

schedule. “I really didn’t know how we

were going to solve the tile problem,”

he recalled. As the challenges mounted,

Cohen, who was under tremendous

pressure from NASA, began going

gray, a fact that his wife attributed to

“every tile it took to put on the vehicle.”

Eventually, engineers came up with a

solution—a process known as

densification, which strengthened the

tiles and, according to Cohen, “bailed

us out of a major, significant problem”

and remained the process throughout

the program.

After more than 10 years of design

and development, the shuttle appeared

ready to fly. In 1979 and 1980, the

Space Shuttle Main Engines proved

their flightworthiness by completing

a series of engine acceptance tests.

The tile installation finally ended, and

the STS-1 crew members, who had

been named in 1978, joked that they

were “130% trained and ready to go”

because of all the time they spent in

the shuttle simulators. Young and

Crippen’s mission marked the beginning

of the shuttle flight test program.

Enterprise atop the Shuttle Carrier Aircraft in a flight above the Mojave Desert, California (1977).

Spaceflight Operations

Columbia’s First Missions

Columbia flew three additional test

flights between 1981 and 1982.

These test flights were designed to

verify the shuttle in space, the testing

and processing facilities, the vehicle’s

equipment, and crew procedures.

Ground testing demonstrated the

capability of the Orbiter, as well as

of its components and systems.

Without flight time, information

about these systems was incomplete.

The four tests were necessary to help

NASA understand heating, loads,

acoustics, and other concepts that

could not be studied on the ground.

This test program ended on July 4,

1982, when commander Thomas

Mattingly landed the shuttle at Dryden

Flight Research Center (DFRC) on the

15,000-ft runway at Edwards Air Force

Base in California. Waiting at the foot

of the steps, President Reagan and

First Lady Nancy Reagan congratulated

the STS-4 crew on a job well done.

Speaking to a crowd of more than

45,000 people at DFRC, the president

said that the completion of this task was

“the historical equivalent to the driving

of the golden spike which completed the

first transcontinental railroad. It marks

our entrance into a new era.”

The operational flights, which followed

the flight test program, fell into several

categories: DoD missions; commercial

satellite deployments; space science

flights; notable spacewalks (also called

extravehicular activities); or satellite

repair and retrieval.

To improve costs, beginning in 1983

all launches and landings at KSC

were managed by one contractor,

Lockheed Space Operations

Company,Titusville, Florida. This

consolidated many functions for the

entire shuttle processing.

Department of Defense Flights

STS-4 (1982) featured the first classified

payload, which marked a fundamental

shift in NASA’s traditionally open

environment. Concerned with national

security, the DoD instructed NASA

Astronauts Mattingly and Henry

Hartsfield to not transmit images of

the cargo bay during the flight, lest

pictures of the secret payload might

inadvertently be revealed. STS-4 did

differ somewhat from the other future

DoD-dedicated flights: there was no

secure communication line, so the crew

worked out a system of communicating

with the ground.

“We had the checklist divided up in

sections that we just had letter names

like Bravo Charlie, Tab Charlie, Tab

The Historical Legacy

Page 19

Discovery

Atlantis

Columbia

Main Engine

Upgrade

*

1986

1987

1988

1989

1990

1991

George H. W. Bush

Ronald Reagan

STS-51L

Challenger Accident

STS-30

Magellan

STS-26

Return to Flight

STS-31

Hubble

Endeavour Construction

*

Columbia

Discovery

Atlantis

Challenger Accidentt

STS-51L

Endeavo

u

oour Construction

Upgrade

Main Engine

R

Magellan

STS-30

n to Flight

Retur

R

SSTS-26

S

Hubble

STS-31

Atlantis

1986

1987

Ronald Reagan

1987

1988

Ronald Reagan

1989

ge H. W

Geor

1990

. Bush

ge H. W

Bravo that they could call out. When we

talked to Sunnyvale [California] to Blue

Cube out there, military control, they

said, ‘Do Tab Charlie,’or something.

That way it was just unclassified,”

Hartsfield recalled. Completely

classified flights began in 1985.

Even though Vandenberg Air Force

Base had been selected as one of the

program launch sites in 1972, the

California shuttle facilities were not

complete when classified flights began.

Anticipating slips, the DoD and NASA

decided to implement a controlled mode

at JSC and KSC that would give the

space agency the capability to control

classified flights out of the Texas and

Florida facilities. Flight controllers at

KSC and JSC used secured launch and

flight control rooms separate from the

rooms used for non-DoD flights.

Modifications were also made to the

flight simulation facility, and a room

was added in the astronaut office, where

flight crew members could store

classified documents inside a safe and

talk on a secure line.

Although the facilities at Vandenberg

Air Force Base were nearly complete in

1984, NASA continued to launch and

control DoD flights. Two DoD missions

flew in 1985: STS-51C and STS-51J.

Each flight included a payload specialist

from the Air Force. That year, the

department also announced the names of

the crew of the first Vandenberg flight,

STS-62A, which would have been

commanded by veteran Astronaut

Robert Crippen, but was cancelled in the

wake of the Challenger accident (1986).

Flying classified flights complicated

the business of spaceflight. For

national security reasons, the Mission

Operations Control Room at JSC was

closed to visitors during simulations

and these flights. Launch time was

not shared with the press and, for the

first time in NASA’s history, no

astronaut interviews were granted

about the flight, no press kits were

distributed, and the media were

prohibited from listening to the

air-to-ground communications.

Shuttle Operations, 1982-1986

STS-5 (1982) marked both the

beginning of shuttle operations and

another turning point in the history

of the Space Shuttle Program. As

Astronaut Joseph Allen explained,

spaceflight changed “from testing the

means of getting into space to using the

resources found there.” Or, put another

way, this four-member crew (the

largest space crew up to that point;

the flight tests never carried more than

two men at a time) was the first to

launch two commercial satellites.

This “initiated a new era in which

the business of spaceflight became

business itself.” Dubbed the “Ace

Moving Company,” the crew jokingly

promised “fast and courteous service”

for its future launch services.

Many of the early shuttle flights were,

in fact, assigned numerous commercial

satellites, which they launched from the

Orbiter’s cargo bay. With NASA given

a monopoly in the domestic launch

market, many flight crews released at

least one satellite on each flight, with

several unloading as many as three

communication satellites for a number

of nations and companies. Foreign

clients, particularly attracted to NASA’s

bargain rates, booked launches early in

the program.

Another visible change that occurred

on this, the fifth flight of Columbia

was the addition of mission

specialists—scientists and engineers—

whose job it was to deploy satellites,

conduct spacewalks, repair and retrieve

malfunctioning satellites, and work

as scientific researchers in space.

The first two mission specialists—

Joseph Allen, a physicist, and William

Lenoir, an electrical engineer—held

PhDs in their respective fields and

had been selected as astronauts in 1967.

Those who followed in their footsteps

had similar qualifications, often

holding advanced degrees in their

fields of study.

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The Historical Legacy

1991

1992

1993

1994

1995

1996

George H. W. Bush

William Clinton

STS-49

Intelsat Repair

STS-61

Hubble Repair

Discovery

Atlantis

Columbia

Endeavour

STS-71

Mir Dock

STS-63

Mir Rendezvous

avour

Endeaa

bia

Columbb

Discovery

Intelsat Repair

STS-49

Discovery

Atlantis

n

sat Repairr

STS-49

Hubble Repair

Mir Ren

STS-61

M

STS-63

S

Mir Dock

STS-71

Mir Rendezvous

1991

1992

. Bush

ge H. W

Geor

Atlantis

1993

n

1994

William Clinton

1995

With the addition of mission specialists

and the beginning of operations, space

science became a major priority for

the shuttle, and crews turned their

attention to research. A variety of

experiments made their way on board

the shuttle in Get Away Specials, the

Shuttle Student Involvement Project,

the middeck (crew quarters), pallets

(unpressurized platforms designed to

support instruments that require direct

exposure to space), and Spacelabs.

Medical doctors within NASA’s own

Astronaut Corps studied space sickness

on STS-7 (1983) and STS-8 (1983),

subjecting their fellow crew members

to a variety of tests in the middeck to

determine the triggers for a problem

that plagues some space travelers.

Aside from medical experiments, many

of the early missions included a variety

of Earth observation instruments.

The crews spent time looking out the

window, identifying and photographing

weather patterns, among other

phenomena. A number of flights

featured material science research,

including STS-61C (1986), which

included Marshall Space Flight

Center’s Material Science Laboratory.

As space research expanded, so

did the number of users, and the

aerospace industry was not excluded

from this list. They were particularly

active in capitalizing on the potential

benefits offered by the shuttle and its

platform as a research facility. Having

signed a Joint Endeavor Agreement

(a quid pro quo arrangement, where

no money exchanged hands) with

NASA in 1980, McDonnell Douglas

Astronautics flew its Continuous Flow

Electrophoresis System on board the

shuttle numerous times to explore the

capabilities of materials processing

in space. The system investigated the

ability to purify erythropoietin (a

hormone) in orbit and to learn whether

the company could mass produce

the purified pharmaceutical in orbit.

The company even sent one of its

employees—who, coincidentally, was

the first industrial payload specialist—

into space to monitor the experiment

on board three flights, including the

maiden flight of Discovery. Other

companies, like Fairchild Industries

and 3M, also signed Joint Endeavor

Agreements with NASA.

When the ninth shuttle flight lifted off

the pad in November 1983, Columbia

had six passengers and a Spacelab in its

payload bay. This mission, the first flight

of European lab, operated 24 hours a

day, featured more than 70 experiments,

The Historical Legacy

Page 21

and carried the first noncommercial

payload specialists to fly in space.

Three additional missions flew

Spacelabs in 1985, with West Germany

sponsoring the flight of STS-61A,

the first mission financed and

operated by another nation. One of

the unique features of this flight

was how control was split between

centers. JSC’s Mission Control

managed the shuttle’s systems and

worked closely with the commander

and pilot while the German Space

Operations Center in Oberpfaffenhofen

oversaw the experiments and

scientists working in the lab.

By 1984, the shuttle’s capabilities

expanded dramatically when Astronauts

Bruce McCandless and Bob Stewart

tested the manned maneuvering units

that permitted flight crews to conduct

untethered spacewalks. At this point in

the program, this was by far the most

demanding spacewalk conducted by

astronauts. The first spacewalk,

conducted just months before the flight

of STS-41B, tested the suits and the

capability of astronauts to work in the

payload bay. As McCandless flew the

unit out of the cargo bay for the first

time, he said, “It may have been one

small step for Neil, but it’s a heck of a

big leap for me.” Set against the

darkness of space, McCandless became

the first human satellite in space.

Having proved the capabilities of the

manned maneuvering unit, NASA

exploited its capabilities and used the

device to make satellite retrieval and

repair possible without the use of the

Shuttle Robotic Arm.

1996

1997

1998

1999

2000

2001

William Clinton

STS-82

Second Hubble Servicing

STS-91

Alpha Magnetic

Spectrometer Test

STS-88

First ISS Mission - 2A

ISS 4A

Discovery

Atlantis

Columbia

Endeavour

Discovery

Endeavouru

Second Hubble Servicing

STS-82

Columbia

Atlantis

a

Serv

ommeter

m

Spectr

agnet

Alpha Maa

STS-91

First ISS Mission - 2A

vicing

v

STS-88

ission - 2

est

Test

Alpha Magnetic

rst ISS Mission - 2A

STS-88

ISISS 4A

1996

1997

Atlantis

1998

William Clinton

a

1999

2000

Christopher Kraft

Director of Johnson Space Center

during shuttle development and early

launches (1972-1982).

Played an instrumental role in the development

and establishment of mission control.

“We went through a lot to prove that we should launch STS-1 manned instead

of unmanned; it was the first time we ever tried to do anything like that.

We convinced ourselves that the reliability was higher and the risk lower,

even though we were risking the lives of two men. We convinced ourselves

that that was a better way to do it, because we didn’t know what else to do.

We had done everything we could think of.”

Early Satellite Repair and Retrievals

Between 1984 and 1985, the shuttle

flew three complicated satellite

retrieval or repair missions. On NASA’s

11th shuttle mission, STS-41C, the

crew was to capture and repair the

Solar Maximum Satellite (SolarMax),

the first one built to be serviced and

repaired by shuttle astronauts. Riding

the manned maneuvering unit,

spacewalker George Nelson tried to

capture the SolarMax, but neither he

nor the Robotic Arm operator Terry

Hart was able to do so. Running

low on fuel, the crew backed away

from the satellite while folks at the

Goddard Space Flight Center in

Page 22

The Historical Legacy

Maryland stabilized the SolarMax.

The shuttle had just enough fuel for

one more rendezvous with the satellite.

Fortunately, Hart was able to grapple

the satellite, allowing Nelson and

James van Hoften to fix the unit,

which was then rereleased into orbit.

The following retrieval mission was

even more complex. STS-51A was the

first mission to deploy two satellites and

then retrieve two others that failed to

achieve their desired orbits. Astronauts

Joseph Allen and Dale Gardner used the

manned maneuvering unit to capture

Palapa and Westar, originally deployed

on STS-41B 9 months earlier. They

encountered problems, however, when

stowing the first recovered satellite,

forcing Allen to hold the 907-kg

(2,000-pound) satellite over his head

for an entire rotation of the Earth—

90 minutes. When the crew members

reported that they had captured and

secured both satellites in Discovery’s

payload bay, Lloyd’s of London—

one of the underwriters for the

satellites—rang the Lutine bell, as they

had done since the 1800s, to announce

events of importance. As Cohen,

former director of JSC, explained,

“Historically Lloyd’s of London,

who would insure high risk adventures,

rang a bell whenever ships returned

to port with recovered treasure from

the sea.” He added that the salvage of

these satellites in 1984 “was at that

time the largest monetary treasure

recovered in history.”

The program developed a plan for the

crew of STS-51I (1985) to retrieve and

repair a malfunctioning Hughes satellite

that had failed to power up just months

before the flight. With only 4 months to

prepare, NASA built a number of tools

that had not been tested in space to

accomplish the crew’s goal. In many

ways, the crew’s flight was a first. Van

Hoften, one of the walkers on STS-41C,

recalled the difference between his

first and second spacewalk: “It wasn’t

anything like the first one. The first one

was so planned out and choreographed.

This one, we were winging it, really.”

Instead of planning their exact moves,

crew members focused instead on skills

and tasks. Their efforts paid off when

the ground activated the satellite.

William Lucas, PhD

Former director of

Marshall Space Flight Center

during shuttle operations

until Challenger accident

(1974-1986).

Played an instrumental

role in Space Shuttle Main

Engine, External Tank,

and Solid Rocket Booster

design, development,

and operations.

“The shuttle was an important part of the total space program and it

accomplished, in a remarkable way, the unique missions for which it was

designed. In addition, as an element of the continuum from the first ballistic

missile to the present, it has been a significant driver of technology for the

benefit of all mankind.”

On October 11, 1974, newly appointed Marshall Space

Flight Center (MSFC) Director Dr. William Lucas (right)

and a former MSFC Director Dr. Wernher von Braun

view a model.

2001

2002

2003

2004

2005

2006

George W. Bush

STS-114

Return to

Flight

ISS 5A

US Lab Destiny

ISS 11A

Inboard Truss

Discovery

Atlantis

Columbia

STS-107

Columbia Accident

Space Station Reemerges

As the Space Shuttle Program matured,

NASA began working on the Space

Station Program, having been directed

to do so by President Reagan in his

1984 State of the Union address.

The shuttle would play an important

role in building the orbiting facility.

In the winter of 1985, STS-61B tested

structures and assembly methods for

the proposed long-duration workshop.

Spacewalkers built a 13.8-m (45-ft)

tower and a 3.7-m (12-ft) structure,

proving that crews could feasibly

assemble structures using parts carried

into space by the Orbiter. NASA

proceeded with plans to build Space

Station Freedom, which in the 1990s

was transformed to the International

Space Station (ISS).

To fund the space station, NASA

needed to cut costs for shuttles by

releasing requests for proposals for

three new contracts. In 1983, the

Shuttle Processing Contract integrated

all processing at KSC. Lockheed

Space Operations Company received

this contract. In 1985, the Space

Transportation Systems Operations

Contract and the Flight Equipment

Contract were solicited. The former

contract consolidated 22 shuttle

operations contracts, while the latter

combined 15 agreements involving

spaceflight equipment (e.g., food,

clothes, and cameras). NASA

Administrator James Beggs hoped that

by awarding such contracts, he could

reduce shuttle costs by as much as a

quarter by putting cost incentives into

the contracts. Rockwell International

won the Space Transportation Systems

Operations Contract, and NASA

chose Boeing Aerospace Operations

to manage the Flight Equipment

Processing Contract.

The Historical Legacy

Page 23

2006

2007

2008

2009

2010

George W. Bush

Barack Obama

ISS 12A

Second Solar Array

ISS 10A

Third Solar Array

STS-118

Educator

Mission

Specialist

STS-134

Alpha Magnetic

Spectrometer,

Station Payload

ISS 20A

Node 3, Cupola

STS-125

Last Hubble Repair

Discovery

Atlantis

Endeavour

STS-133

PROJECTED

2011

STS-134

Endeavour

I

Atlantis

Second SSo

S

ISS 12A

IS

Discovery

Challenger Accident

In January 1986, NASA suspended all

shuttle flights after the Challenger

accident in which seven crew members

perished. A failure in the Solid Rocket

Booster motor joint caused the

vehicle to break up. The investigation

board was very critical of NASA

management, especially about the

decision to launch. For nearly 3 years,

NASA flew no shuttle flights. Instead,

the agency made changes to the

shuttle. It added a crew escape system

and new brakes, improved the main

engines, and redesigned the Solid

Rocket Boosters, among other things.

In the aftermath of the accident, the

agency made several key decisions,

which were major turning points.

The shuttle would no longer deliver

commercial satellites into Earth orbit

unless “compelling circumstances”

existed or the deployment required the

unique capabilities of the space truck.

This decision forced industry and

foreign governments who hoped to

deploy satellites from the shuttle to

turn to expendable launch vehicles.

Fletcher, who had returned for a

second term as NASA administrator,

cancelled the Shuttle/Centaur Program

because it was too risky to launch the

shuttle carrying a rocket with highly

combustible liquid fuel. Plans to

finally activate and use the Vandenberg

Air Force Base launch site were

abandoned, and the shuttle launch site

was eventually mothballed. The Air

Force decided to launch future

payloads on Titan rockets and ordered

additional expendable launch vehicles.

A few DoD-dedicated missions

would, however, fly after the accident.

Finally, in 1987, Congress authorized

the building of Endeavour as a

replacement for the lost Challenger.

Endeavour was delivered to KSC in

the spring of 1991.

Post-Challenger Accident

Return to Flight

STS-26 was the Space Shuttle’s Return

to Flight. Thirty-two months after the

Challenger accident, Discovery roared

to life on September 29,1988, taking

its all-veteran crew into space where

they deployed the second Tracking and

Data Relay Satellite. The crew safely

returned home to DFRC 4 days later,

and Vice President George H.W. Bush

and his wife Barbara Bush greeted the

crew. That mission was a particularly

significant accomplishment for NASA.

STS-26 restored confidence in the

agency and marked a new beginning

for NASA’s human spaceflight program.

Building Momentum

Following the STS-26 flight, the

shuttle’s launch schedule climbed once

again, with the space agency eventually

using all three shuttles in the launch

processing flow for upcoming missions.

The first four flights after the accident

alternated between Discovery and

Atlantis, adding Columbia to the mix for

STS-28 (1989). Even though the flight

crews did not launch any commercial

satellites from the payload bay, several

deep space probes—the Magellan Venus

Radar Mapper, Galileo, and Ulysses—

required the shuttle’s unique

capabilities. STS-30 (1989) launched the

mapper, which opened a new era

of exploration for the agency. This was

the first time a Space Shuttle crew

deployed an interplanetary probe,

thereby interlocking both the manned

and unmanned spaceflight programs.

In addition, this flight was NASA’s first

planetary mission of any kind since

1977, when it launched the Voyager

spacecraft. STS-34 (1989) deployed the

Galileo spacecraft toward Jupiter.

Finally, STS-41 (1990) delivered the

European Space Agency’s Ulysses

spacecraft, which would study the polar

regions of the sun.

Extended Duration Orbiter Program

Before 1988, shuttle flights were short,

with limited life science research.

NASA thought that if the shuttle could

be modified, it could function as a

microgravity laboratory for weeks at a

time. The first stage was to make

modifications to the life support, air,

water, and waste management systems

for up to a 16-day stay. There were

potential drawbacks to extended stays

in microgravity. Astronauts were

concerned about the preservation of

their capability for unaided egress from

the shuttle, including the capability

for bailout. Another concern was

degradation of landing proficiency

after such a long stay, as this had never

been done before.

Between 1992 (STS-50) and 1995,

this program successfully demonstrated

that astronauts could land and egress

after such long stays, but that significant

muscle degradation occurred. The

addition of a new pressurized g-suit

provided relief to the light-headedness

(feeling like fainting) experienced

when returning to Earth. Improvements

Page 24

included the addition of a crew transport

vehicle that astronauts entered directly

from the landed shuttle in which they

reclined during medical examination

until they were ready to walk. On-orbit

exercise was tested to improve their

physical capabilities for emergency

egress and landing. The research

showed that with more than 2 weeks of

microgravity, astronauts probably

should not land the shuttle as it was too

complicated and risky. In the future,

shuttle landing would only be performed

by a short-duration astronaut.

The Historical Legacy

Astronaut James Voss is pictured during an

STS-69 (1995) extravehicular activity that was

conducted in and around Endeavour’s cargo bay.

Voss and Astronaut Michael Gernhardt performed

evaluations for space station-era tools and

various elements of the spacesuits.

The Great Observatories

Months before the Ulysses deployment,

the crew of STS-31 (1990) deployed the

Hubble Space Telescope, which had

been slated for launch in August 1986

but slipped to 1990 after the Challenger

accident. Weeks before the launch,

astronauts and NASA administrators

laid out the importance of the flight.

Lennard Fisk, NASA’s associate

administrator for Space Science and

Applications, explained, “This is a

mission from which (people) can expect

very fundamental discoveries. They

could begin to understand creation.

Hubble could be a turning point in

humankind’s perception of itself and its

place in the universe.”

Unfortunately, within just a few short

months NASA discovered problems

with the telescope’s mirror—problems

that generated a great deal of

controversy. Several in Congress

believed that the telescope was a

colossal waste of money. Only 4 years

after the accident, NASA’s morale

plunged again. Fortunately, the flight

and ground crews, along with

employees at Lockheed Martin, took

the time to work out procedures to

service the telescope in orbit during the

flight hiatus. In 1992, NASA named the

crew that would take on this challenge.

The astronauts assigned to repair the

telescope felt pressure to succeed.

“Everybody was looking at the servicing

and repair of the Hubble Space

Telescope as the mission that could

prove NASA’s worth,” Commander

Dick Covey recalled. The mission

was one of the most sophisticated ever

planned at NASA. The spacewalkers

rendezvoused for the first time with the

telescope, one of the largest objects

the shuttle had rendezvoused with at

that point, and conducted a record-

breaking five spacewalks. The repairs

were successful, and the public faith

rebounded. Four additional missions

serviced the Hubble, with the final

launching in 2009.

Two other major scientific payloads,

part of NASA’s Great Observatories

including the Compton Gamma Ray

Observatory and the Chandra X-ray

Observatory, launched from the

Orbiter’s cargo bay. When the Compton

Gamma Ray Observatory’s high-gain

antenna failed to deploy, Astronauts

Jerry Ross and Jay Apt took the first

spacewalk in 6 years (the last walk

occurred in 1985) and freed the

antenna. The crew of STS-93, which

featured NASA’s first female mission

commander, Eileen Collins, delivered

the Chandra X-ray Observatory to

Earth orbit in 1999.

Satellite Retrieval and Repair

Satellite retrieval and repair missions all

but disappeared from the shuttle

manifest after the Challenger accident.

STS-49 (1992) was the one exception.

An Intelsat was stranded in an improper

orbit for several years, and spacewalkers

from STS-49 were to attach a new kick-

start motor to it.The plan seemed simple

enough. After all, NASA had plenty

of practice capturing ailing satellites.

After two unsuccessful attempts, flight

controllers developed a plan that

required a three-person spacewalk,

a first in the history of NASA’s space

operations. This finally allowed the

crew to repair and redeploy the satellite,

which occurred—coincidentally—

during Endeavour’s first flight.

New Main Engine

STS-70 flew in the summer of 1995

and launched a Tracking and Data

Relay Satellite. The shuttle flew the

new main engine, which contained an

improved high-pressure liquid oxygen

turbopump, a two-duct powerhead,

and a single-coil heat exchanger.

The new pumps were a breakthrough

in shuttle reliability and quality, for

they were much safer than those

previously used on the Orbiter. The

turbopumps required less maintenance

than those used prior to 1995. Rather

than removing each pump after every

flight, engineers would only have to

conduct detailed inspections of the

pumps after six missions. A single-coil

heat exchanger eliminated many of

the welds that existed in the previous

pump, thereby increasing engine

reliability, while the powerhead

enhanced the flow of fuel in the engine.

Space Laboratories

NASA continued to fly space laboratory

missions until 1998, when Columbia

launched the final laboratory and crew

into orbit for the STS-90 mission. The

shuttle had two versions of the payload

bay laboratory: European Spacelab

and US company Spacehab, Inc. Fifteen

years had passed since the flight of

STS-9—the first mission—and the

project ended with the launch of

Neurolab, which measured the impact

of microgravity on the nervous system:

blood pressure; eye-hand coordination;

motor coordination; sleep patterns; and

the inner ear. Scientists learned a great

deal from Spacelab Life Sciences-1 and

-2 missions, which flew in the summer

of 1991 and 1993, respectively, and

The Historical Legacy

Page 25

represented a turning point in spaceflight

human physiology research. Previous

understandings of how the human body

worked in space were either incomplete

or incorrect. The program scientist for

the flight explained that the crew

obtained “a significant number of

surprising results” from the flight.

Other notable flights included the

ASTRO-1 payload, which featured four

telescopes designed to measure

ultraviolet light from astronomical

objects, life sciences missions, the US

Microgravity Labs, and even a second

German flight called D-2. The day

before the crew of D-2 touched down

at DFRC on an Edwards Air Force

Base runway, the Space Shuttle

Program reached a major milestone,

having accrued a full year of flight

time by May 5,1993.

Spacehab, a commercially provided

series of modules similar to Spacelab

and used for science and logistics, was

a significant part of the shuttle

manifest in the 1990s. One of those

Spacehab flights featured the return of

Mercury 7 Astronaut and US Senator

John Glenn, Jr. Thirty-six years had

passed since he had flown in space and

had become the first American to fly

in Earth orbit. He broke records again

in 1998 when he became the oldest

person to fly in space. Given his age,

researchers hoped to compare the

similarities between aging on Earth

with the effects of microgravity on the

human body. Interest in this historic

flight, which also fell on NASA’s 40th

anniversary, was immense. Not only

was Glenn returning to orbit, but

Pedro Duque—a European Space

Agency astronaut—became the first

Spanish astronaut, following in the

footsteps of Spanish explorers Hernán

Cortés and Francisco Pizarro.

Consolidating Contracts

The Space Shuttle Program seemed

to hit its stride in the 1990s. In 1995,

NASA decided to consolidate 12

individual contracts under a single

prime contractor. United Space

Alliance (USA), a hybrid venture

between Rockwell International and

Lockheed Martin, became NASA’s

selection to manage the space agency’s

Space Flight Operations Contract.

USA was the obvious choice because

those two companies combined held

nearly 70% of the dollar value of prime

shuttle contracts. Although the idea

of handing over all processing and

launch operations to a contractor was

controversial, NASAAdministrator

Daniel Goldin, known for his “faster,

better, cheaper” mantra, enthusiastically

supported the sole source contract as

part of President William Clinton’s

effort to trim the federal budget and

increase efficiency within government.

NASA awarded USA a $7 billion

contract, which went into effect on

October 1,1996. Speaking at JSC about

the agreement, Goldin proclaimed,

“Today is the first day of a new space

program in America. We are opening

up the space program to commercial

space involving humans. May it

survive and get stronger.”

STS-80, the first mission controlled

by USA, launched in November 1996.

The all-veteran crew, on the final flight

of the year and the 80th of the program,

stayed in space for a record-breaking

17 days. A failure with the hatch

prohibited crew members from

conducting two scheduled spacewalks,

but NASA considered the mission a

success because the crew brought home

more scientific data than they had

expected to gather with the Orbiting and

Retrievable Far and Extreme Ultraviolet

Spectrometer-Shuttle Pallet Satellite-II.

Page 26

The Historical Legacy

US Senator John Glenn, Jr., payload specialist, keeps up his busy test agenda during Flight Day 7

on board Discovery STS-95 in 1998. This was a Spacehab flight that studied the effect of microgravity

on human physiology. He is preparing his food, and on the side is the bar code reader used to record

all food, fluids, and drug intakes.

The Shuttle-Mir Program

As the Cold War (the Soviet-US conflict

between the mid 1940s and early

1990s) ended, the George H.W. Bush

administration began laying the

groundwork for a partnership in space

between the United States and the

Soviet Union. Following the collapse

of the Soviet Union in 1991, President

Bush and Russian President Boris

Yeltsin signed a space agreement,

in June 1992, calling for collaboration

between the two countries in space.

They planned to place American

astronauts on board the Russian space

station Mir and to take Russian

cosmonauts on board shuttle flights.

Noting the historic nature of the

agreement, Goldin said, “Our children

and their children will look upon

yesterday and today as momentous

events that brought our peoples

together.” This agreement brokered a

new partnership between the world’s

spacefaring nations, once adversaries.

Known as the Shuttle-Mir Program,

these international flights were the

first phase of the ISS Program and

marked a turning point in history.

The Shuttle-Mir Program—led from

JSC, with its director George Abbey—

was a watershed and a symbol of the

thawing of relations between the United

States and Russia.

For more than 4 years, from the winter

of 1994 to the summer of 1998, nine

shuttle flights flew to the Russian space

station, with seven astronauts living on

board the Mir for extended periods of

time. The first phase began when

Cosmonaut Sergei Krikalev flew on

board STS-60 (1994).

Twenty years had passed since the

Apollo-Soyuz Test Project when, in the

summer of 1995, Robert Gibson made

history when he docked Atlantis to the

much-larger Mir. The STS-71 crew

members exchanged gifts and shook

hands with the Mir commander in the

docking tunnel that linked the shuttle

and the Russian station. They dropped

off the next Mir crew and picked up two

cosmonauts and America’s first resident

of Mir, Astronaut Norman Thagard.

Additional missions ferried crews and

necessary supplies to Mir. One of the

major milestones of the program was the

STS-74 (1995) mission, which delivered

and attached a permanent docking port

to the Russian space station.

In 1996, Astronaut Shannon Lucid

broke all American records for time

in orbit and held the flight endurance

record for all women, from any nation,

when she stayed on board Mir for

188 days. Clinton presented Lucid

with the Congressional Space Medal

of Honor for her service, representing

the first time a woman or scientist

had received this accolade. Speaking

about the importance of the Shuttle-Mir

Program, the president said, “Her

mission did much to cement the

alliance in space we have formed with

Russia. It demonstrated that, as we

move into a truly global society, space

exploration can serve to deepen our

understanding, not only of our planet

and our universe, but of those who

share the Earth with us.”

STS-91 (1998), which ended shuttle

visits to Mir, featured the first flight of

the super-lightweight External Tank.

Made of aluminum lithium, the newly

designed tank weighed 3,402 kg

(7,500 pounds) less than the previous

tank (the lightweight or second-

generation tank) used on the previous

flight, but its metal was stronger

than that flown prior to the summer

of 1998. By removing so much launch

weight, engineers expanded the shuttle’s

ability to carry heavier payloads,

like the space station modules, into

Earth’s orbit. Launching with less

weight also enabled the crew to fly to

a high inclination orbit of 51.6 degrees,

where NASA and its partners would

build the ISS. STS-91 also carried a

prototype of the Alpha Magnetic

Spectrometer into space. This

instrument was designed to look for

dark and missing matter in the universe.

The preliminary test flight was in

preparation for its launch to the ISS

on STS-134. The Alpha Magnetic

Spectrometer has a state-of-the-art

particle physics detector, and includes

the participation of 56 institutions and

16 countries led by Nobel Laureate

Samuel Ting. By the end of the

Shuttle-Mir Program, the number of

US astronauts who visited the Russian

space station exceeded the number

of Russian cosmonauts who had

worked aboard Mir.

The International Space Station

With the first phase completed, NASA

began constructing the ISS with the

assistance of shuttle crews, who

played an integral role in building the

outpost. In 1998, 13 years after

spacewalker Jerry Ross demonstrated

the feasibility of assembling structures

in space (STS-61B [1985]), ISS

construction began. During three

spacewalks, Ross and James Newman

connected electrical power and cables

between the Russian Zarya module

and America’s Unity Module, also

called Node 1. They installed additional

hardware—handrails and antennas—

on the station. NASA’s dream of

building a space station had finally

come to fruition.

The Historical Legacy

Page 27

The shuttle’s 100th mission (STS-92)

launched from KSC in October 2000,

marking a major milestone for the

Space Shuttle and the International

Space Station Programs. The

construction crew delivered and

installed the initial truss—the first

permanent latticework structure—which

set the stage for the future addition of

trusses. The crew also delivered a

docking port and other hardware to

the station. Four spacewalkers spent

more than 27 hours outside the shuttle

as they reconfigured these new elements

onto the station. The seven-member

crew also prepared the station for the

first resident astronauts, who docked

with the station 14 days after the crew

left the orbital workshop. Of the

historic mission, Lead Flight Director

Chuck Shaw said, “STS-92/ISS

Mission 3A opens the next chapter

in the construction of the International

Space Station,” when human beings

from around the world would

permanently occupy the space base.

Crews began living and working in

the station in the fall of 2000, when the

first resident crew (Expedition 1) of

Sergei Krikalev, William Shepherd,

and Yuri Gidzenko resided in the space

station for 4 months. For the next

3 years, the shuttle and her crews were

the station’s workhorse. They

transferred crews; delivered supplies;

installed modules, trusses, the Space

Station Robotic Arm, an airlock, and

a mobile transporter, among other

things. By the end of 2002, NASA

had flown 16 assembly flights. Flying

the shuttle seemed fairly routine until

February 2003, when Columbia

disintegrated over East Texas, resulting

in the loss of the shuttle and her

seven-member crew.

Columbia Accident

The cause of the Columbia accident

was twofold. The physical cause

resulted from the loss of insulating

foam from the External Tank, which

hit the Orbiter’s left wing during launch

and created a hole. When Columbia

Page 28

entered the Earth’s atmosphere,

the left wing leading edge thermal

protection (reinforced carbon-carbon

panels) was unable to prevent

heating due to the breach. This led

to the loss of control and disintegration

of the shuttle, killing the crew.

NASA’s flawed culture of

complacency also bore responsibility

for the loss of the vehicle and its

astronauts. All flights were put on

hold for more than 2 years as NASA

implemented numerous safety

improvements, like redesigning the

External Tank with an improved

bipod fitting that minimized potential

foam debris from the tank. Other

improvements were the Solid Rocket

Booster Bolt Catcher, impact sensors

added to the wing’s leading edge, and a

boom for the shuttle’s arm that allowed

the crew to inspect the vehicle for any

possible damage, among other things.

As NASA worked on these issues,

President George W. Bush announced

his new Vision for Space Exploration,

which included the end of the Space

Shuttle Program. As soon as possible,

the shuttles would return to flight to

complete the ISS by 2010 and then

NASA would retire the fleet.

The Historical Legacy

Although no astronauts are visible in this picture, action was brisk outside the Space Shuttle (STS-116)/space station tandem in 2006.

Post-Columbia Accident

Return to Flight

In 2005, STS-114 returned NASA to

flying in space. Astronaut Eileen

Collins commanded the first of two

Return to Flight missions, which

were considered test flights. The first

mission tested and evaluated new

flight safety procedures as well as

inspection and repair techniques

for the vehicle. One of the changes

was the addition of an approximately

15-m (50-ft) boom to the end of the

robotic arm. This increased astronauts’

capabilities to inspect the tile located

The Historical Legacy

Page 29

on the underbelly of the shuttle.

When NASA discovered two gap

fillers sticking out of the tiles on the

shuttle’s belly on the first mission,

flight controllers and the astronauts

came up with a plan to remove

the gap fillers—an unprecedented and

unplanned spacewalk that they

believed would decrease excessive

temperatures on re-entry. The plan

required Astronaut Stephen Robinson

to ride the arm underneath the shuttle

and pull out the fillers. In 24 years

of shuttle operations, this had never

been attempted, but the fillers were

easily removed. STS-114 showed

that improvements in the External

Tank insulation foam were

insufficient to prevent dangerous

losses during ascent. Another year

passed before STS-121 (2006), the

second Return to Flight mission, flew

after more improvements were made

to the foam applications.

Leroy Chiao, PhD

Astronaut on STS-65 (1994),

STS-72 (1996), and STS-92 (2000).

Commander and science officer on

ISS Expedition 10 (2004-2005).

“To me, the Space Shuttle is an

amazing flying machine. It

launches vertically as a rocket,

turns into an extremely capable

orbital platform for many

purposes, and then becomes an

airplane after re-entry into the

atmosphere for landing on a conventional runway. Moreover, it is a reusable

vehicle, which was a first in the US space program.

“The Space Shuttle Program presented me the opportunity to become a NASA

astronaut and to fly in space. I never forgot my boyhood dream and years later

applied after watching the first launch of Columbia. In addition to being a superb

research and operations platform, the Space Shuttle also served as a bridge to

other nations. Never before had foreign nationals flown aboard US spacecraft.

On shuttle, the US had flown representatives from nations all around the world.

Space is an ideal neutral ground for cooperation and the development of better

understanding and relationships between nations.

“Without the Space Shuttle as an extravehicular activity test bed, we would

not have been nearly as successful as we have been so far in assembling

the ISS. The Space Shuttle again proved its flexibility and capability for ISS

construction missions.

“Upon our landing (STS-92), I realized that my shuttle days were behind me.

I was about to begin training for ISS. But on that afternoon, as we walked around

and under Discovery, I savored the moment and felt a mixture of awe, satisfaction,

and a little sadness. Shuttle, to me, represents a triumph and remains to this day

a technological marvel. We learned so much from the program, not only in the

advancement of science and international relations, but also from what works and

what doesn’t on a reusable vehicle. The lessons learned from shuttle will make

future US spacecraft more reliable, safer, and cost effective.

“I love the Space Shuttle. I am proud and honored to be a part of its history

and legacy.”

Final Flights

Educator Astronaut

Excitement began to build at NASA

and across the nation as the date

for Barbara Morgan’s flight, STS-118

(2007), grew closer. Morgan had

been selected as the backup for

Christa McAuliffe, NASA’s first

Teacher in Space in 1985. After the

Challenger accident, Morgan became

the Teacher in Space Designee

and returned to teaching in Idaho.

She came back to Houston in 1998

when she was selected as an astronaut

candidate. More than 20 years after

being selected as the backup Teacher

in Space, Morgan fulfilled that dream

by serving as the first educator mission

specialist. NASAAdministrator

Michael Griffin praised Morgan

“for her interest, her toughness, her

resiliency, her persistence in wanting

to fly in space and eventually doing

so.” Adults recalled the Challenger

accident and watched this flight with

interest. STS-118 drew attention from

students, from across America and

around the globe, who were curious

about the flight.

Return to Hubble

In May 2009, the crew of STS-125

made the final repairs and upgrades to

the Hubble Space Telescope to ensure

quality science for several more years.

This flight was a long time coming due

to the Columbia accident, after which

NASA was unsure whether it could

continue to fly to destinations with no

safe haven such as the ISS.

With the ISS, if problems arose,

especially with the thermal protection,

the astronauts could stay in the space

station until either another shuttle or

the Russian Soyuz could bring them

home. The Hubble orbited beyond the

ability for the shuttle to get to the ISS

if the shuttle was critically damaged.

Thus, for several years, the agency had

vetoed any possibility that NASA could

return to the telescope.

At that point, the Hubble had been

functioning for 12 years in the very

hostile environment of space. Not only

did its instruments eventually wear out,

but the telescope needed important

upgrades to expand its capabilities.

After the Return to Flight of STS-114

and STS-121, NASA reevaluated the

ability to safety return astronauts after

launch. The method to ensure safe

return in the event of shuttle damage

was to have a backup vehicle in place.

So in 2009, Atlantis launched to

repair the telescope, with Endeavour

as the backup.

Improvements on the International

Space Station Continued

Discovery flight STS-128, in 2009,

provided capability for six crew

members for ISS. This was a major

milestone for ISS as the station had

been operating with two to three crew

members since its first occupation

in 1999. The shuttle launched most of

the ISS, including Canadian, European,

and Japanese elements, to the orbiting

laboratory. In 2010, Endeavour provided

the final large components: European

Space Agency Node 3 with additional

hygiene compartment; and Cupola

with a robotic work station to assist

in assembly/maintenance of the ISS and

a window for Earth observations.

As of December 2010, NASA

manifested two more shuttle flights:

STS-133 and STS-134.

Page 30

The Historical Legacy

This Commemorative Patch celebrates the

30-year life and work of the Space Shuttle

Program. Selected from over 100 designs, this

winning patch by Mr. Blake Dumesnil features

the historic icon set within a jewel-shape frame.

It celebrates the shuttle’s exploration within

low-Earth orbit, and our desire to explore beyond.

Especially poignant are the seven stars on each

side of the shuttle, representing the 14 lives

lost—seven on Columbia, seven on Challenger—

in pursuit of their dream, and this nation’s dream

of further exploration and discovery. The five

larger stars represent the shuttles that made up

the fleet—each shuttle a star in its own right.

The Historical Legacy

Page 31

Changes in Mission Complexity Over Nearly 3 Decades

Length of flight as mission days. Early flights lasted less than 1

week, but, as confidence grew, some flights lasted 14 to 15 days.

Crew size started at two—a commander and pilot—and

grew to routine flights with six crew members. During the

Shuttle-Mir and International Space Station (ISS) Programs,

the shuttle took crew members to the station and returned

crew members, for a total of seven crew members.

Deploys occurred throughout the program. During the first

10 years, these were primarily satellites with sometimes more

than one per flight. Some satellites, such as Hubble Space

Telescope, were returned to the payload bay for repair. With

construction of the ISS, several major elements were deployed.

Components of Mission Complexity

Over the 30 years of the Space Shuttle Program, missions became more complex with increased understanding of the use of this vehicle,

thereby producing increased capabilities. This diagram illustrates the increasing complexity as well as the downtime between the major

accidents—Challenger and Columbia.

Rendezvous included every time the shuttle connected to an

orbiting craft from satellites, to Hubble, Mir, and ISS. Some flights

had several rendezvous.

Extravehicular activity (EVA) is determined as EVA crew days.

Many flights had no EVAs, while others had one every day with

two crew members.

Secret Department of Defense missions were very complex.

Spacelabs were missions with a scientific lab in the payload bay.

Besides the complexity of launch and landing, these flights

included many scientific studies.

Construction of the ISS by shuttle crew members.

Who heard the whispers that were coming from the shuttle’s Solid Rocket

Boosters (SRBs) on a cold January morning in 1986? Who thought the mighty

Space Shuttle, designed to withstand the thermal extremes of space, would be

negatively affected by launching at near-freezing temperatures? Very few

understood the danger, and most of the smart people working in the program

missed the obvious signs. Through 1985 and January 1986, the dedicated and

talented people at the NASA Human Spaceflight Centers focused on readying

the Challenger and her crew to fly a complex mission. Seventy-three seconds

after SRB ignition, hot gases leaking from a joint on one of the SRBs impinged

on the External Tank (ET), causing a structural failure that resulted in the loss

of the vehicle and crew.

Most Americans are unaware of the profound and devastating impact the

accident had on the close-knit NASA team. The loss of Challenger and

her crew devastated NASA, particularly at Johnson Space Center (JSC) and

Marshall Space Flight Center (MSFC) as well as the processing crews at

Kennedy Space Center (KSC) and the landing and recovery crew at Dryden

Flight Research Center. Three NASA teams were primarily responsible for

shuttle safety—JSC for on-orbit operation and crew member issues;

MSFC for launch propulsion; and KSC for shuttle processing and launch.

Each center played its part in the two failures. What happened to the

“Failure is not an option” creed, they asked. The engineering and operations

teams had spent months preparing for this mission. They identified many

failure scenarios and trained relentlessly to overcome them. The ascent flight

control team was experienced with outstanding leadership and had practiced

for every contingency. But on that cold morning in January, all they could

do was watch in disbelief as the vehicle and crew were lost high above the

Atlantic Ocean. Nothing could have saved the Challenger and her crew once

the chain of events started to unfold. On that day, everything fell to pieces.

Seventeen years later, in 2003, NASA lost a second shuttle and crew—Space

Transportation System (STS)-107. The events that led up to the loss of

Columbia were eerily similar to those surrounding Challenger. As with

Challenger, the vehicle talked to the program but no one understood. Loss of

foam from the ET had been a persistent problem in varying degrees for the

entire program. When it occurred on STS-107, many doubted that a

lightweight piece of foam could damage the resilient shuttle. It made no

sense, but that is what happened. Dedicated people missed the obvious. In

the end, foam damaged the wing to such an extent that the crew and vehicle

could not safely reenter the Earth’s atmosphere. Just as with Challenger,

there was no opportunity to heroically “save the day” as the data from the

vehicle disappeared and it became clear that friends and colleagues were

lost. Disbelief was the first reaction, and then a pall of grief and devastation

descended on the NASA family of operators, engineers, and managers.

Page 32

The Historical Legacy

The Accidents:

A Nation’s

Tragedy, NASA’s

Challenge

Randy Stone

Jennifer Ross-Nazzal

The Crew

Michael Chandler

Philip Stepaniak

Witness Accounts—Key to

Understanding Columbia Breakup

Paul Hill

The Challenger Accident

Pressure to Fly

As the final flight of Challenger

approached, the Space Shuttle Program

and the operations community at JSC,

MSFC, and KSC faced many pressures

that made each sensitive to maintaining

a very ambitious launch schedule. By

1986, the schedule and changes in the

manifest due to commercial and

Department of Defense launch

requirements began to stress NASA’s

ability to plan, design, and execute

shuttle missions. NASA had won

support for the program in the 1970s by

emphasizing the cost-effectiveness and

economic value of the system. By

December 1983, 2 years after the

maiden flight of Columbia, NASA had

flown only nine missions. To make

spaceflight more routine and therefore

more economical, the agency had to

accelerate the number of missions it

flew each year. To reach this goal,

NASA announced an ambitious rate of

24 flights by1990.

NASA flew five missions in 1984 and a

record nine missions the following year.

By 1985, strains in the system were

evident. Planning, training, launching,

and flying nine flights stressed the

agency’s resources and workforce, as

did the constant change in the flight

manifest. Crews scheduled to fly in 1986

would have seen a dramatic decrease

in their number of training hours or the

agency would have had to slow down

its pace because NASA simply lacked

the staff and facilities to safely fly an

accelerated number of missions.

By the end of 1985, pressure mounted

on the space agency as they prepared to

launch more than one flight a month the

next year. A record four launch scrubs

and two launch delays of STS-61C,

which finally launched in January 1986,

exacerbated tensions. To ensure that

no more delays would threaten the

1986 flight rate or schedule, NASA cut

the flight 1 day short to make sure

Columbia could be processed in time

for the scheduled ASTRO-1 science

mission in March. Weather conditions

prohibited landing that day and the

next, causing a slip in the processing

schedule. NASA had to avoid any

additional delays to meet its goal of

15 flights that year.

The agency needed to hold to the

schedule to complete at least three

flights that could not be delayed.

Two flights had to be launched in

May 1986: the Ulysses and the Galileo

flights, which were to launch within

6 days of each other. If the back-to-back

flights missed their launch window,

the payloads could not be launched

until July 1987. The delay of STS-61C

and Challenger’s final liftoff in January

threatened the scheduled launch plans

of these two flights in particular. The

Challenger needed to launch and deploy

a second Tracking and Data Relay

Satellite, which provided continuous

global coverage of Earth-orbiting

satellites at various altitudes. The shuttle

would then return promptly to be

reconfigured to hold the liquid-fueled

Centaur rocket in its payload bay.

The ASTRO-1 flight had to be launched

in March or April to observe Halley’s

Comet from the shuttle.

On January 28, 1986, NASA launched

Challenger, but the mission was

never realized. Hot gases from the

right-hand Solid Rocket Booster motor

had penetrated the thermal barrier

and blown by the O-ring seals on the

booster field joint. The joints were

designed to join the motor segments

together and contain the immense heat

and pressure of the motor combustion.

As the Challenger ascended, the leak

became an intense jet of flame that

penetrated the ET, resulting in

structural failure of the vehicle and

loss of the crew.

Prior to this tragic flight, there had

been many O-ring problems witnessed

as early as November 1981 on the

second flight of Columbia. The hot

gases had significantly eroded the

STS-2 booster right field joint—deeper

than on any other mission until the

accident—but knowledge was not

widespread in mission management.

STS-6 (1983) boosters did not have

erosion of the O-rings, but heat had

impacted them. In addition, holes were

blown through the putty in both nozzle

joints. NASA reclassified the new

field joints Criticality 1, noting that the

failure of a joint could result in “loss of

life or vehicle if the component fails.”

Even with this new categorization,

the topic of O-ring erosion was not

discussed in any Flight Readiness

Reviews until March 1984, in

preparation for the 11th flight of the

program. Time and again these

anomalies popped up in other missions

flown in 1984 and 1985, with the

issue eventually classified as an

“acceptable risk” but not desirable.

The SRB project manager regularly

waived these anomalies, citing them as

“repeats of conditions that had already

been accepted for flight” or “within

their experience base,” explained

Arnold Aldrich, program manager for

the Space Shuttle Program.

Senior leadership like Judson

Lovingood believed that engineers

“had thoroughly worked that joint

problem.” As explained by former

Chief Engineer Keith Coates, “We

knew the gap was opening. We knew

The Historical Legacy

Page 33

the O-rings were getting burned.

But there’d been some engineering

rationale that said, ‘It won’t be a

failure of the joint.’And I thought

justifiably so at the time I was there.

And I think that if it hadn’t been for

the cold weather, which was a whole

new environment, then it probably

would have continued. We didn’t like

it, but it wouldn’t fail.”

Each time the shuttle launched

successfully, the accomplishment

masked the recurring field joint

problems. Engineers and managers

were fooled into complacency because

they were told it was not a flight safety

issue. They concluded that it was safe

to fly again because the previous

missions had flown successfully. In

short, they reached the same conclusion

each time—it was safe to fly another

mission. “The argument that the same

risk was flown before without failure is

often accepted as an argument for the

safety of accepting it again. Because of

this, obvious weaknesses are accepted

again and again, sometimes without a

sufficiently serious attempt to remedy

them or to delay a flight because of

their continued presence,” wrote

Richard Feynman, Nobel Prize winner

and member of the presidential-

appointed Rogers Commission charged

to investigate the Challenger accident.

Operational Syndrome

The Space Shuttle Program was also

“caught up in a syndrome that the

shuttle was operational,” according to

J.R.Thompson, former project manager

for the Space Shuttle Main Engines.

The Orbital Flight Test Program, which

ended in 1982, marked the beginning of

routine operations of the shuttle, even

though there were still problems with

the booster joint. Nonetheless, MSFC

and Morton Thiokol, the company

responsible for the SRBs, seemed

confident with the design.

Although the design of the boosters

had proven to be a major complication

for MSFC and Morton Thiokol, the

engineering debate occurring behind

closed doors was not visible to the entire

Space Shuttle Program preparing for the

launch of STS-51L. There had been

serious erosions of the booster joint

seals on STS-51B (1985) and STS-51C

(1985), but MSFC had not pointed out

any problems with the boosters right

before the Challenger launch.

Furthermore, MSFC failed to bring

the design issue, failures, or concern

with launching in cold temperatures to

the attention of senior management.

Instead, discussions of the booster

engines were resolved at the local level,

even on the eve of the Challenger

launch. “I was totally unaware that these

meetings and discussions had even

occurred until they were brought to light

several weeks following the Challenger

accident in a Rogers Commission

hearing at KSC,”Arnold Aldrich

recalled. He also recalled that he had

sat shoulder to shoulder with senior

management “in the firing room for

approximately 5 hours leading up to the

launch of Challenger and no aspect of

these deliberations was ever discussed

or mentioned.”

Even the flight control team “didn’t

know about what was lurking on the

booster side,” according to Ascent

Flight Director Jay Greene. Astronaut

Richard Covey, then working as capsule

communicator, explained that the team

“just flat didn’t have that insight” into

the booster trouble. Launch proceeded

and, in fewer than 2 minutes, the joint

failed, resulting in the loss of seven

lives and the Challenger.

Looking back over the decision, it is

difficult to understand why NASA

launched the Challenger that morning.

The history of troublesome technical

issues with the O-rings and joint are

easily documented. In hindsight, the

trends appear obvious, but the data had

not been compiled. Wiley Bunn noted,

“It was a matter of assembling that data

and looking at it [in] the proper fashion.

Had we done that, the data just jumps

off the page at you.”

Devastated

The accident devastated NASA

employees and contractors. To this

day Aldrich asks himself regularly,

“What could we have done to prevent

what happened?” Holding a mission

management team meeting the morning

of launch might have brought up the

Thiokol/MSFC teleconference the

previous evening. “I wish I had made

such a meeting happen,” he lamented.

The flight control team felt some

responsibility for the accident,

remembered STS-51L Lead Flight

Director Randy Stone. Controllers

“truly believed they could handle

absolutely any problem that this vehicle

could throw at us.” The accident,

however, “completely shattered the

belief that the flight control team can

always save the day. We have never

fully recovered from that.” Alabama

and Florida employees similarly

felt guilty about the loss of the crew

and shuttle, viewing it as a personal

failure. John Conway of KSC pointed

out that “a lot of the fun went out of

the business with that accident.”

Rebounded

Over time, the wounds began to heal

and morale improved as employees

reevaluated the engineering design and

process decisions of the program. The

KSC personnel dedicated themselves to

the recovery of Challenger and returning

as much of the vehicle back to the

launch site as possible. NASA spent the

next 2½ years fixing the hardware and

improving processes, and made over

200 changes to the shuttle during this

downtime. Working on design changes

to improve the vehicle contributed to the

healing process for people at the centers.

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The Historical Legacy

Making the boosters and main engines

more robust became extremely

important for engineers at MSFC and

Thiokol. The engineers and astronauts

at JSC threw themselves into

developing an escape system and

protective launch and re-entry suits

and improving the flight preparation

process. All of the improvements

then had to be incorporated into the

KSC vehicle processing efforts.

All NASA centers concentrated on how

they could make the system better and

safer. For civil servants and contractors,

the recovery from the accident was not

just business. It was personal. Working

toward Return to Flight was almost a

religious experience that restored the

shattered confidence of the workforce.

NASA instituted a robust flight

preparation process for the Return to

Flight mission, which focused on safety

and included a series of revised

procedures and processes at the centers.

At KSC, for instance, new policies

were instituted for 24-hour operations

to avoid the fatigue and excessive

overtime noted by the Rogers

Commission. NASA implemented the

NASA Safety Reporting System. Safety,

reliability, maintainability, and quality

assurance staff increased considerably.

The Historical Legacy

Page 35

The Crew

Following the breakup of Challenger

(STS-51L) during launch over the Atlantic

Ocean on January 28, 1986, personnel

in the Department of Defense STS

Contingency Support Office activated the

rescue and recovery assets. This included

the local military search and rescue

helicopters from the Eastern Space and

Missile Center at Patrick Air Force Base and

the US Coast Guard. The crew compartment

was eventually located on March 8, and

NASA officially announced that the recovery

operations were completed on April 21.

The recovered remains of the crew were

taken to Cape Canaveral Air Force Station

and then transported, with military honors,

to the Armed Forces Institute of Pathology

where they were identified. Burial

arrangements were coordinated with the

families by the Port Mortuary at Dover

Air Force Base, Delaware. Internal NASA

reports on the mechanism of injuries

sustained by the crew contributed to

upgrades in training and crew equipment

that supported scenarios of bailout,

egress, and escape for Return to Flight.

Following the breakup of Columbia

(STS-107) during re-entry over Texas and

Louisiana on February 1, 2003, personnel

from the NASA Mishap Investigation Team

were dispatched to various disaster field

offices for crew recovery efforts.The Lufkin,

Texas, office served as the primary area

for all operations, including staging assets

and deploying field teams for search,

recovery, and security. Many organizations

had operational experience with disaster

recovery, including branches of the federal,

state, and local governments together with

many local citizen volunteers. Remains of

all seven crew members were found within

a 40- by 3-km (25- by 2-mile) corridor in

East Texas.The formal search for crew

members was terminated on February 13,

2003.Astronauts, military, and local police

personnel transported the crew, with honors,

to Barksdale Air Force Base, Louisiana, for

preliminary identification and preparation

for transport.The crew was then relocated,

with military honor guard and protocol,

to the Armed Forces Institute of Pathology

medical examiner for forensic analysis.

Burial preparation and arrangements were

coordinated with the families by the Port

Mortuary at Dover Air Force Base, Delaware.

Additional details on the mechanism of

injuries sustained by the crew and lessons

learned for enhanced crew survival are

found in the Columbia Crew Survival

Investigation Report NASA/SP-2008-565.

Reconstruction of the Columbia from parts found in East Texas. From this layout, NASA was

able to determine that a large hole occurred in the leading edge of the wing and identify the

burn patterns that eventually led to the destruction of the shuttle.

JSC’s Mission Operations Director

Eugene Kranz noted that Mission

Operations examined “every job we

do” during the stand down. They

microscopically analyzed their

processes and scrutinized those

decisions. They learned that the flight

readiness process prior to the

Challenger accident frequently lacked

detailed documentation and was often

driven more by personality than by

requirements. The process was never

identical or exact but unique. Changes

were made to institute a more rigorous

program, which was well-documented

and could be instituted for every flight.

Astronaut Robert Crippen became the

deputy director of the National Space

Transportation System Operations.

He helped to determine and establish

new processes for running and

operating the flight readiness review

and mission management team (headed

by Crippen), as well as the launch

commit criteria procedures, including

temperature standards. He instituted

changes to ensure the agency

maintained clear lines of responsibility

and authority for the new launch

decision process he oversaw.

Retired Astronaut Richard Truly also

participated in the decision-making

processes for the Return to Flight effort.

Truly, then working as associate

administrator for spaceflight, invited the

STS-26 (1988) commander Frederick

Hauck to attend any management

meetings in relation to the preparation

for flight. By attending those meetings,

Hauck had “confidence in the fixes

that had been made” and “confidence in

the team of people that had made those

decisions,” he remarked.

Return to Flight

After Challenger Accident

As the launch date for the flight

approached, excitement began to build

at the centers. Crowds surrounded

the shuttle when it emerged from the

Vehicle Assembly Building on

July 4, 1988. The Star-Spangled Banner

played as the vehicle crawled to the

pad, while crew members and other

workers from KSC and Headquarters

spoke about the milestone. David

Hilmers, a member of the crew, tied the

milestone to the patriotism of the day.

“What more fitting present could we

make to our country on the day of its

birth than this? America, the dream

is still alive,” he exclaimed. The Return

to Flight effort was a symbol of

America’s pride and served as a healing

moment not only for the agency but

also for the country. Tip Talone of

KSC likened the event to a “rebirth.”

Indeed, President Ronald Reagan, who

visited JSC in September 1988, told

workers, “When we launch Discovery,

even more than the thrust of great

engines, it will be the courage of our

heroes and the hopes and dreams of

every American that will lift the shuttle

into the heavens.”

Without any delays, the launch

of STS-26 went off just a few days

after the president’s speech, returning

Americans to space. The pride in

America’s accomplishment could be

seen across the country. In Florida,

the Launch Control Center raised

a large American flag at launch time

and lowered it when the mission

concluded. In California, at Dryden

Flight Research Center, the astronauts

exited the vehicle carrying an

American flag—a patriotic symbol

of their flight. Cheering crowds

waving American flags greeted the

astronauts at the crew return event at

Ellington Field in Houston, Texas.

The launch restored confidence

in the program and the vehicle. Pride

and excitement could be found across

the centers and at contract facilities

around the country.

The Columbia Accident

NASA flew 87 successful missions

following the Return to Flight effort.

As the 1990s unfolded, the post-

Challenger political and economic

environment changed dramatically.

Environment Changes

As the Soviet Union disintegrated

and the Soviet-US conflict that began

in the mid 1940s came to an end,

NASA (established in 1958) struggled

to find its place in a post-Cold War

world. Around the same time, the

federal deficit swelled to a height that

raised concern among economists and

citizens. To cut the deficit, Congress

and the White House decreased

domestic spending, and NASA was not

spared from these cuts. Rather than

eliminate programs within the agency,

NASA chose to become more

cost-effective. A leaner, more efficient

agency emerged with the appointment

of NASAAdministrator Daniel Goldin

in 1992, whose slogan was “faster,

better, cheaper.”

The shuttle, the most expensive line

item in NASA’s budget, underwent

significant budget reductions throughout

the 1990s. Between 1993 and 2003, the

program suffered from a 40% decrease

in its purchasing capability (with

inflation included in the figures), and its

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The Historical Legacy

The Historical Legacy

Page 37

workforce correspondingly decreased.

To secure additional cost savings,

NASA awarded the Space Flight

Operations Contract to United Space

Alliance in 1995 to consolidate

numerous shuttle contracts into one.

Pressure Leading up to the Accident

As these changes took effect, NASA

began working on Phase One of the

Space Station Program, called

Shuttle-Mir. Phase Two, assembly of

the ISS, began in 1998. The shuttle was

critical to the building of the outpost

and was the only vehicle that could

launch the modules built by Europe,

Japan, and the United States. By tying

the two programs so closely together,

a reliable, regular launch schedule was

necessary to maintain crew rotations,

so the ISS management began to dictate

NASA’s launch schedule. The program

had to meet deadlines outlined in

bilateral agreements signed in 1998.

Even though the shuttle was not an

operational vehicle, the agency worked

its schedules as if the space truck could

be launched on demand, and there

was increasing pressure to meet a

February 2004 launch date for Node 2.

When launch dates slipped, these

delays affected flight schedules.

On top of budget constraints, personnel

reductions, and schedule pressure, the

program suffered from a lack of vision

on replacing the shuttle. There was

uncertainty about the program’s lifetime.

Would the shuttle fly until 2030 or be

replaced with new technology? Ronald

Dittemore, manager of the Space Shuttle

Program from 1999 to 2003, explained,

“We had no direction.” NASA would

“start and stop” funding initiatives, like

the shuttle upgrades, and then reverse

directions. “Our reputation was kind of

sullied there, because we never finished

what we started out to do.”

This was the environment in which

NASA found itself in 2003. On the

morning of January 16, Columbia

launched from KSC for a lengthy

research flight. On February 1, just

minutes from a successful landing in

Florida, the Orbiter broke up over

East Texas and Louisiana. Debris

littered its final path. The crew and

Columbia were lost.

Recovering Columbia and Her Crew

Recovery of the Orbiter and its crew

began at 9:16 a.m., when the ship

failed to arrive in Florida. The rapid

response and mishap investigation

teams from within the agency headed

to Barksdale Air Force Base in

Shreveport, Louisiana. Hundreds of

NASA employees and contractors

reported to their centers to determine

how they could help bring the crew

and Columbia home. Local emergency

service personnel were the first

responders at the various scenes.

By that evening, representatives from

local, state, and federal agencies were

in place and ready to assist NASA.

The recovery effort was unique, quite

unlike emergency responses following

other national disasters. David Whittle,

head of the mishap investigation team,

recalled that there were “130 state,

federal, and local agencies” represented

in the effort; but as he explained, we

“never, ever had a tiff. Matter of fact,

the Congressional Committee on

Homeland Security sent some people

down to interview us to figure out how

we did that, because that was not the

experience of 9/11.” The priority of the

effort was the recovery of the vehicle

and the astronauts, and all of these

agencies came together to see to it that

NASA achieved this goal.

While in East Texas and Louisiana, the

space agency came to understand how

important the Space Shuttle Program

was to the area and America. Volunteers

traveled from all over the United States

to help in the search. People living in the

area opened their arms to the thousands

of NASA employees who were grieving.

They offered their condolences, while

some local restaurants provided free

food to workers. Ed Mango, KSC

launch manager and director of the

recovery for approximately 3 months,

learned “that people love the space

program and want to support it in any

way they can.” His replacement, Jeff

Angermeier, added, “When you work in

the program all the time, you care

deeply about it, but it isn’t glamorous to

you. Out away from the space centers,

NASA is a big deal.”

As volunteers collected debris, it

was shipped to KSC where the vehicle

was reconstructed. For the center’s

employees, the fact that Columbia

would not be coming back whole was

hard to swallow. “I never thought I’d

see Columbia going home in a box,”

said Michael Leinbach of KSC. Many

others felt the same way. Working with

the debris and reconstructing the ship

did help, however, to heal the wounds.

As with the loss of Challenger, NASA

employees continue to be haunted by

questions of “what if.” “I’ll bet you a

day hardly goes by that we don’t think

about the crew of Columbia and if there

was something we might have been able

to do to prevent” the accident, admitted

Dittemore. Wayne Hale, shuttle program

manager for launch integration at KSC,

called the decisions made by the mission

management team his“biggest” regret.

“We had the opportunity to really save

the day, we really did, and we just didn’t

do it, just were blind to it.”

Causes

Foam had detached from the ET since

the beginning of the program, even

though design requirements specifically

prohibited shedding from the tank.

Columbia sustained major damage on

its maiden flight, eventually requiring

the replacement of 300 tiles. As early

as 1983, six other missions witnessed

the left tank bipod ramp foam loss that

eventually led to the loss of the STS-107

crew and vehicle. For more than 20

years, NASA had witnessed foam

shedding and debris hits. Just one flight

after STS-26 (the Return to Flight after

Challenger), Atlantis was severely

damaged by debris that resulted in the

loss of one tile.

Two flights prior to the loss of Columbia

and her crew, STS-112 (2002)

experienced bipod ramp loss, which hit

both the booster and tank attachment

ring. The result was a 10.2-cm- (4-in.)-

wide, 7.6-cm- (3 in.)-deep tear in the

insulation. The program assigned the ET

Project with the task of determining the

cause and a solution. But the project

failed to understand the severity of foam

loss and its impact on the Orbiter, so the

due date for the assignment slipped to

after the return of STS-107.

Foam loss became an expected anomaly

and was not viewed as risky. Instead,

the issue became one the program had

regularly experienced, and one that

engineers believed they understood.

It was never seen as a safety issue.

The fact that previous missions, which

had experienced severe debris hits, had

successfully landed only served to

reinforce confidence within the program

concerning the robustness of the vehicle.

After several months of investigation

and speculation about the cause of the

accident, investigators determined that

a breach in the tile on the left wing led

to the loss of the vehicle. Insulation

foam from the ET’s left bipod ramp,

which damaged the wing’s reinforced

carbon-carbon panel, created the gap.

During re-entry, superheated air entered

the breach. Temperatures were so

extreme that the aluminum in the left

wing began to melt, which eventually

destroyed it and led to a loss of vehicle

control. Columbia experienced

aerodynamic stress that the damaged

airframe could not withstand, and

the vehicle eventually broke up over

East Texas and Louisiana.

Senior program management had been

alerted to the STS-107 debris strike on

the second day of the flight but had

failed to understand the risks to the crew

or the vehicle. No one thought that foam

could create a hole in the leading edge

of the wing. Strikes had been within

their experience base. In short,

management made assumptions based

on previous successes, which blinded

them to serious problems. “Even in

flight when we saw (the foam) hit the

wing, it was a failure of imagination

that it could cause the damage that it

undoubtedly caused,” said John

Shannon, who later became manager of

the Space Shuttle Program. Testing later

proved that foam could create cracks in

the reinforced carbon-carbon and holes

of 40.6 by 43.2 cm (16 by 17 in.).

Aside from the physical cause of the

accident, flaws within the decision-

making process also significantly

impacted the outcome of the STS-107

flight. A lack of effective and clear

communication stemmed from

organizational barriers and hierarchies

within the program. These obstacles

made it difficult for engineers with

real concerns about vehicle damage to

share their views with management.

Investigators found that management

accepted opinions that mirrored their

own and rejected dissent.

Changes

The second Return to Flight effort

focused on reducing the risk of failures

documented by the Columbia Accident

Investigation Board. The focus was on

improving risk assessments, making

system improvements, and

implementing cultural changes in

workforce interaction. In the case of

improved risk assessments, Hale

explained, “We [had] reestablished the

old NASA culture of doing it right,

relying more on test and less on talk,

requiring exacting analysis, doing our

homework.” As an example, he cited

the ET-120, which was to have been the

Return to Flight tank for STS-114 and

was to be sent to KSC late in 2004.

But, he admitted, “We knew there

[were] insufficient data to determine the

tank was safe to fly.” After the Debris

Verification Review, management

learned that some minor issues still had

to be handled before these tanks would

be approved for flight.

During the flight hiatus, NASA

upgraded many of the shuttle’s systems

and began the process of changing its

culture. Engineers redesigned the

boosters’ bolt catcher and modified the

tank in an attempt to eliminate foam

loss from the bipod ramp. Engineers

developed an Orbiter Boom Sensor

System to inspect the tiles in space,

and NASA added a Wing Leading

Edge Impact Detection System. NASA

also installed a camera on the ET

umbilical well to document separation

and any foam loss.

Finally, NASA focused on improving

communication and listening to

dissenting opinions. To help the agency

implement plans to open dialogue

between managers and engineers, from

the bottom up, NASA hired the global

safety consulting firm Behavioral

Science Technology, headquartered in

Ojai, California.

Return to Flight

After Columbia Accident

When the crew of STS-114 finally

launched in the summer of 2005, it was

a proud moment for the agency and the

country. President George W. Bush,

who watched the launch from the Oval

Office’s dining room, said, “Our space

program is a source of great national

pride, and this flight is an essential step

toward our goal of continuing to lead

the world in space science, human

spaceflight, and space exploration.”

First Lady Laura Bush and Florida

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The Historical Legacy

Page 39

Governor Jeb Bush were among the

guests at KSC. Indeed, the Return

to Flight mission had been a source

of pride for the nation since its

announcement. For instance, troops in

Iraq sent a “Go Discovery” banner that

was hung at KSC. At the landing at

Dryden Flight Research Center, the

astronauts exited the vehicle carrying an

American flag. When the crew returned

to Ellington Field, a huge crowd greeted

the crew, waving flags as a symbol of

the nation’s accomplishment. Houston

Mayor Bill White declared August 10,

2005, “Discovery STS-114 Day.”

Standing on a stage, backed by a giant

American flag, the crew thanked

everyone for their support.

Witness Accounts—Key to Understanding Columbia Breakup

The early sightings assessment team—

formed 2 days after the Space Shuttle

Columbia accident on February 1,2003—

had two primary goals:

n

Sift through and characterize the witness

reports during re-entry.

n

Obtain and analyze all available data to

better characterize the pre-breakup debris

and ground impact areas.This included

providing the NASA interface to the

Department of Defense (DoD) through the

DoD Columbia Investigation Support Team.

Of the 17,400 public phone, e-mail, and

mail reports received from February 1

through April 4, more than 2,900 were

witness reports during re-entry, prior

to the vehicle breakup. Over 700 of those

included photographs or video. Public

imagery provided a near-complete

record of Columbia’s re-entry and video

showed debris being shed from the

shuttle. Final analysis revealed 20 distinct

debris shedding events and three

flashes/flares during re-entry. Analysis of

these videos and corresponding air traffic

control radar produced 20 pre-breakup

search areas, ranging in size from 2.6 to

4,403 square km (1 to 1,700 square miles)

extending from the California-Nevada

border through West Texas.

To facilitate the trajectory analysis, witness

reports were prioritized to process re-entry

imagery with precise observer location and

time calibration first.The process was to

time-synchronize all video, determine the

exact debris shedding time, measure relative

motion, determine ballistic properties of the

debris, and perform trajectory analysis to

predict the potential ground impact areas

or footprints. Key videos were hand carried,

expedited through the photo assessment

team, and put into ballistic and trajectory

analysis as quickly as possible.The

Aerospace Corporation independently

performed the ballistic and trajectory

analysis for process verification.

The public reports, which at first seemed

like random information, were in fact

a diamond in the rough. This information

became invaluable for the search teams

on the ground. The associated trajectory

analyses also significantly advanced

the study of spacecraft breakup in the

atmosphere and the subsequent ground

impact footprints.

13:53:46

Debris 1

13:53:48

Debris 2

13:55:23 to 13:55:27

Debris Shower A

13:55:24

Debris 8

13:54:36

Debris 6

13:54:33

Flash 1

13:53:56

Debris 3

13:54:02

Debris 4

13:54:09

Debris 5

13:55:05

Debris 7

13:55:27

Debris 10

13:55:37

Debris 11

13:55:45

Debris 12

13:55:39

Debris 11A

13:55:40

Debris 11B

13:55:44

Debris 11C

13:55:56

Debris 13

13:55:58

Debris 14

13:56:10

Debris 15

13:57:24

Debris 16

13:59:47

Debris A

14:00:02

Debris B

14:00:03

Debris C

14:00:10

Debris D

14:00:11

Debris E

14:00:12

Debris F

14:00:15

Debris Shower

14:00:18.3

Catastrophic

Event

14:00:05.7

Late Flash 1

14:00:06.7

Late Flash 2

13:58:00

Flare 2

13:57:54

Flare 1

13:55:18

Debris 7A

Hours: Minutes: Seconds

STS-107 Global Positioning Satellite Trajectory

STS-107 Predicted Trajectory

Debris Event

Video Observer

Major City

00:00:00 =

Houston

Austin

El Paso

Phoenix

Los

Angeles

San

Diego

San

Francisco

San Antonio

Fort

Worth Dallas

co

7

o t

s

allas

W

F

After the Columbia broke apart over East

Texas, volunteers from federal agencies,

as well as members of the East Texas First

Responders, participated in walking the

debris fields, forest, and wetlands to find

as many parts as possible. This facilitated

in determining the cause of the accident.

Impact of the Accidents

on NASA

The two shuttle tragedies shook NASA’s

confidence and have significantly

impacted the agency in the long term.

At the time of both accidents, the Space

Shuttle Program office, astronauts, and

flight and launch control teams were

incredibly capable and dedicated to

flying safely. Yet, from the vantage

point of hindsight, these teams

overlooked the obvious, allowing two

tragedies to unfold on the public stage.

Many of the people directly involved

in those flights remain haunted by the

realization that their decisions resulted

in the loss of human lives. NASA was

responsible for the safety of the crew

and vehicles, and they failed. The

flight control teams who worked

toward perfection with the motto of

“Failure is not an option” felt

responsible and hesitant to make hard

decisions. Likewise, the engineering

communities at JSC and MSFC, and

the KSC team that prepared the

vehicles, shared feelings of guilt and

shaken confidence.

The fact that these tragedies occurred

in front of millions of spectators and

elected officials made the aftermath

even more difficult for the NASA team.

The American public and the elected

officials expected perfection. When it

was not delivered, the outcry of “How

could this have happened?” made the

headlines of every newspaper and

television newscast and became a topic

of concern in Congress. The second

accident was harder on the agency

because the question was now: “How

could this have happened again?”

Because of the accidents, the agency

had a more difficult challenge in

convincing Congress of NASA’s

ability to safely fly people in space.

That credibility gap made each NASA

administrator’s job more difficult and

raised doubts in Congress about

whether human spaceflight was worth

the risk and money. To this day, doubts

have not been fully erased on the value

of human spaceflight, and the questions

of safety and cost are at the forefront of

every yearly budget cycle.

In contrast with American politicians,

the team of astronauts, engineers, and

support personnel that makes human

spaceflight happen believes that space

exploration must continue. “Yes, there

is risk in space travel, but I think that

it’s safe enough that I’m willing to take

the risk,” STS-114 (2005) Commander

Eileen Collins admitted before her final

flight. “I think it’s much, much safer

than what our ancestors did in traveling

across the Atlantic Ocean in an old

ship. Frankly, I think they were crazy

doing that, but they wanted to do that,

and we need to carry on the human

exploration of the universe that we live

in. I’m honored to be part of that and

I’m proud to be part of it. I want to be

able to hand on that belief or

enthusiasm that I have to the younger

generation because I want us to

continue to explore.”

Without this core belief, the individuals

who picked up the pieces after both

accidents could not have made it

through those terrible times. All of the

human spaceflight centers—KSC,

MSFC, and JSC—suffered terribly from

the loss of Challenger and Columbia.

The personnel of all three centers

recovered by rededicating themselves

to understanding what caused the

accidents and how accidents could be

prevented in the future. Together, they

found the problems and fixed them.

Did the agency change following

these two accidents? The answer is

absolutely. Following the Challenger

accident, the teams looked at every

aspect of the processes used to prepare

for a shuttle mission. As a result, they

went from the mentality that every

flight was completely new with a

custom solution to a mindset that

included a documented production

process that was repeatable, flight

after flight. The flight readiness

process evolved from a process of

informally asking each element if all

was flight ready to a well-documented

set of processes that required

specific questions be answered and

documented for presentation to

management at a formal face-to-face

meeting. A rigorous process emerged

across the engineering and the

operations elements at the centers

that made subsequent flights safer.

Yet in spite of all the formal processes

put in place, Columbia was still lost.

These procedures were not flawed,

but the decision-making process was

flawed with regard to assessing the

loss of foam. Tommy Holloway, who

served for several years as the Space

Shuttle Program manager, observed

that the decision to fly had been based

on previous success and not on the

analysis of the data.

Since 2003, NASA has gone to great

lengths to improve the processes to

determine risk and how the team

handles difficult decisions. A major

criticism of NASA following the

Columbia accident was that managers

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The Historical Legacy

did not always listen to minority and

dissenting positions. NASA has since

diligently worked toward transforming

the culture of its employees to be

inclusive of all opinions while working

toward a solution.

In hindsight, NASA should not have

made an “OK to fly” decision for the

final missions of Challenger and

Columbia. NASA depended on the

requirements that went into the Launch

Commit Criteria and Flight Rules to

assure that the shuttle was safe to fly.

Since neither flight had a “violation”

of these requirements, the missions

were allowed to proceed even though

some people were uncomfortable

with the conditions. As a result, NASA

has emphasized that the culture should

be “prove it is safe” as opposed to

“prove it is unsafe” when a concern is

raised. The process is better, and the

culture is changing as a result of both

of these accidents.

As a tribute to the human spirit, teams

did not quit or give up after either

accident but rather pressed on to Return

to Flight each time with a better-

prepared and more robust vehicle and

team. Some individuals never fully

recovered, and they drifted away from

human spaceflight. The majority,

however, stayed with a renewed vigor

to find ways to make spaceflight safer.

They still believe in the creed “Failure

is not an option” and work diligently to

meet the expectation of perfection by

the American people and Congress.

NASA has learned from past mistakes

and continues on with ventures in

space exploration, recognizing that

spaceflight is hard, complex, and—

most importantly—will always have

inherent risk. Accidents will happen,

and the teams will have to dig deep into

their inner strength to find a way to

recover, improve the system, and

continue the exploration of space for

future generations.

The Historical Legacy

Page 41

On an Occasion

of National Mourning

Howard Nemerov

Poet Laureate of the United States

1963-1964 and 1988-1990

It is admittedly difficult for a whole

Nation to mourn and be seen to do so, but

It can be done, the silvery platitudes

Were waiting in their silos for just such

An emergent occasion, cards of sympathy

From heads of state were long ago prepared

For launching and are bounced around the world

From satellites at near the speed of light,

The divine services are telecast

From the home towns, children are interviewed

And say politely, gravely, how sorry they are,

And in a week or so the thing is done,

The sea gives up its bits and pieces and

The investigating board pinpoints the cause

By inspecting bits and pieces, nothing of the sort

Can ever happen again, the prescribed course

Of tragedy is run through omen to amen

As in a play, the nation rises again

Reborn of grief and ready to seek the stars;

Remembering the shuttle, forgetting the loom.

© Howard Nemerov. Reproduced with permission of the copyright owner. Al rights reserved.

To fully understand the story of the development of the Space Shuttle,

it is important to consider the national defense context in which it was

conceived, developed, and initially deployed.

The Cold War between the United States and the Union of Soviet

Socialist Republics (USSR), which had played such a large role in the

initiation of the Apollo Program, was also an important factor in the

decisions that formed and guided the Space Shuttle Program. The United

States feared that losing the Cold War (1947-1991) to the USSR could

result in Soviet mastery over the globe. Since there were few direct

conflicts between the United States and the USSR, success in space was

an indicator of which country was ahead—which side was winning.

Having lost the tactical battles of first satellite and first human in orbit,

the United States had recovered and spectacularly won the race to the

moon. To counter the successful US man-on-the-moon effort, the USSR

developed an impressive space station program. By the early 1980s, the

USSR had launched a series of space stations into Earth orbit. The

Soviets were in space to stay, and the United States could not be viewed

as having abdicated leadership in space after the Apollo Program.

The need to clearly demonstrate the continued US leadership in space

was an important factor in the formation of the Space Shuttle Program.

While several other programs were considered, NASA ultimately

directed their planning efforts to focus on a reusable, crewed booster

that would provide frequent, low-cost access to low-Earth orbit.

This booster would launch all US spacecraft, so there would have to be

direct interaction between the open, civilian NASA culture and the

Defense-related National Security Space (NSS) programs. Use of the

civilian NASA Space Shuttle Program by the NSS programs was

controversial, with divergent goals, and many thought it was a

relationship made for political reasons only—not in the interest of

national security. The relationship between these two very different

cultures was often turbulent and each side had to change to

accommodate the other. Yet it was ultimately successful, as seen in

the flawless missions that followed.

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The Historical Legacy

National

Security

Jeff DeTroye

James Armor

Sebastian Coglitore

James Grogan

Michael Hamel

David Hess

Gary Payton

Katherine Roberts

Everett Dolman

National Security

Space Programs

The Department of Defense uses space

systems in support of air, land, and

sea forces to deter and defend against

hostile actions directed at the interests

of the United States. The Intelligence

community uses space systems to collect

intelligence. These programs, as a group,

are referred to as National Security

Space (NSS). Despite having a single

name, the NSS did not have a unified

management structure with authority

over all programs.

Since the beginning of the space era,

these defense-related space missions had

been giving the president, as well as

defense and intelligence leadership in

the United States, critical insights into

the actions and intents of adversaries.

In 1967, President Lyndon Johnson said,

“I wouldn’t want to be quoted on this—

we’ve spent $35 or $40 billion on the

space program. And if nothing else had

come out of it except the knowledge that

we gained from space photography, it

would be worth 10 times what the whole

program has cost. Because tonight we

know how many missiles the enemy has

and, it turned out, our guesses were way

off. We were doing things we didn’t

need to do. We were building things we

didn’t need to build. We were harboring

fears we didn’t need to harbor.” Due to

these important contributions and others,

the NSS programs had a significant

amount of political support and funding.

As a result, both the NSS program

leadership and the NASA program

leadership often held conflicting views

of which program was more important

and, therefore, whose position on a

given issue ought to prevail.

These two characteristics of the NSS

programs—lack of unified NSS

program management and a competing

view of priorities—would cause

friction between NASA and the NSS

programs management throughout the

duration of the relationship.

1970-1981: Role

of National Security

Space Programs

in Development of

the Shuttle

The National Security Space (NSS)

is often portrayed as having forced

design requirements on NASA to

gain NSS commitment to the Space

Shuttle Program. In reality, NASA was

interested in building the most capable

(and largest) shuttle that Congress

and the administration would approve.

It is true that NSS leaders argued for a

large payload bay and a delta wing to

provide a 1,600-km (1,000-mile) cross

range for landing. NASA, however,

also wanted a large payload bay for

space station modules as well as for

spacecraft and high-energy stage

combinations. NASA designers

required the shuttle to be able to land

at an abort site, one orbit after launch

from the West Coast, which would

also require a delta wing. Indeed,

NASA cited the delta wing as an

essential NASA requirement, even

for launches from the East Coast.

NASA was offered the chance to build

a smaller shuttle when, in January

1972, President Richard Nixon

approved the Space Transportation

System (STS) for development.

The NASA leadership decided to stick

with the larger, delta wing design.

National Space Policy: The

Shuttle as Sole Access to Space

The Space Shuttle Program was

approved with the widely understood

but unstated policy that when it

became operational it would be used

to launch all NSS payloads. The

production of all other expendable

launch vehicles, like the reliable

Titan, would be abandoned. In 1981,

shortly after the launch of STS-1, the

National Space Transportation Policy

signed by President Ronald Reagan

formalized this position: “The STS

will be the primary space launch

system for both United States military

and civil government missions.

The transition to the shuttle should

occur as expeditiously as practical. . . .

Launch priority will be provided to

national security missions, and such

missions may use the shuttle as

dedicated mission vehicles.”

This mandated dependence on the

shuttle worried NSS leaders, with

some saying the plan was “seriously

deficient, both operationally and

economically.” In January 1984,

Secretary of Defense Caspar

Weinberger directed the purchase

of additional expendable boosters

because “total reliance upon the

STS for sole access to space in view

of the technical and operational

uncertainties, represents an

unacceptable national security risk.”

This action, taken 2 years before

the Challenger accident, ensured that

expendable launch vehicles would be

available for use by the NSS programs

in the event of a shuttle accident.

Furthermore, by 1982 the full costs

of shuttle missions were becoming

clearer and the actual per-flight cost

of a shuttle mission had risen to

over $280 million, with a Titan

launch looking cheap in comparison

at less than $180 million. With the

skyrocketing costs of a shuttle launch,

the existence of an expendable

launch vehicles option for the NSS

programs made the transition from the

shuttle inevitable.

Military “Man in Space”

To this day, the US Air Force (USAF)

uses flight crews for most of their

airborne missions. Yet, there was

much discussion within the service

about the value of having a military

human in space program. Through

the 1960s, development of early

reconnaissance satellites like Corona

The Historical Legacy

Page 43

demonstrated that long-life

electronics and complex systems

on the spacecraft and on the ground

could be relied on to accomplish

the crucial task of reconnaissance.

These systems used inexpensive

systems on orbit and relatively

small expendable launch vehicles,

and they proved that human

presence in space was not necessary

for these missions.

During the early 1960s, NSS had

two military man in space programs:

first the “Dyna Soar” space plane, and

then the Manned Orbiting Laboratory

program. Both were cancelled, largely

due to skepticism on the part of the

Department of Defense (DoD) or

NSS leadership that the programs’

contributions were worth the expense

as well as the unwanted attention that

the presence of astronauts would bring

to these highly classified missions.

Although 14 military astronauts

were chosen for the Manned Orbiting

Laboratory program, the sudden

cancellation of this vast program in

1969 left them, as well as the nearly

completed launch facility at

Vandenberg Air Force Base, California,

without a mission. With NASA’s

existing programs ramping down,

NASA was reluctant to take the

military astronauts into its Astronaut

Corps. Eventually, only the seven

youngest military astronauts

transferred to NASA. The others

returned to their military careers.

These military astronauts did not fly

until the 1980s, with the first being

Robert Crippen as pilot on STS-1.

The Manned Orbiting Laboratory

pad at Vandenberg Air Force Base

would lie dormant until the early

1980s when modifications were begun

for use with the shuttle.

The Space Shuttle Program plans

included a payload specialist selected

for a particular mission by the payload

sponsor or customer. Many NSS

leadership were not enthusiastic

about the concept; however, in 1979,

a selection board made up of NSS

leadership and a NASA representative

chose the first cadre of 13 military

officers from the USAF and US Navy.

These officers were called manned

spaceflight engineers. There was

considerable friction with the NASA

astronaut office over the military

payload specialist program. Many of

the ex-Manned Orbiting Laboratory

astronauts who had been working at

NASA and waiting for over a decade

to fly in space were not enthusiastic

about the NSS plans to fly their own

officers as payload specialists. In the

long run, NASA astronauts had little

to be concerned about. When asked

his opinion of the role of military

payload specialists in upcoming

shuttle missions, General Lew Allen,

then chief of staff of the USAF,

related a story about when he played

a major role in the cancellation of

the Manned Orbiting Laboratory

Military Man in Space program.

In 1984, another NSS senior wrote:

“The major driver in the higher STS

costs is the cost of carrying man on a

mission which does not need man. . . .

It is clear that man is not needed on

the transport mission. . . .” The NSS

senior leadership was still very

skeptical about the need for a military

man in space. Ultimately, only two

NSS manned spaceflight engineers

flew on shuttle missions.

Launch System Integration:

Preparing for Launch

The new partnership between NASA

and the NSS programs was very

complex. Launching the national

security payloads on the shuttle

required the cooperation of two large,

proud organizations, each of which

viewed their mission as being

of the highest national priority. This

belief in their own primacy was a part

of each organization’s culture. From

the very beginning, it was obvious

that considerable effort would be

required by both organizations to forge

a true partnership. At the beginning

of the Space Shuttle Program, NASA

focused on the shuttle, while NSS

program leaders naturally focused on

the spacecraft’s mission. As the

partnership developed, NASA had

to become more payload focused.

Much of the friction was over who

was in charge. The NSS programs

were used to having control of the

launch of their spacecraft. NASA kept

firm control of the shuttle missions

and struggled with the requests for

unique support from each of the many

programs using the shuttle.

Launch system integration—the

process of launching a spacecraft on

the shuttle—was a complex activity

that had to be navigated successfully.

For an existing spacecraft design,

transitioning to fly on the shuttle

required a detailed engineering and

safety assessment. Typically, some

redesign was required to make the

spacecraft meet the shuttle’s

operational and safety requirements,

such as making dangerous propellant

and explosive systems safe for a

crewed vehicle. This effort actually

offered an opportunity for growth

due to the shuttle payload bay size

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The Historical Legacy

and the lift capacity from the Kennedy

Space Center (KSC) launch site.

Typically flying alone on dedicated

missions, the NSS spacecraft had all

the shuttle capacity to grow into.

Since design changes were usually

required for structural or safety

reasons, most NSS program managers

could not resist taking at least some

advantage of the available mass or

volume. So many NSS spacecraft

developed during the shuttle era were

much larger than their predecessors

had been in the late 1960s.

National Security Space

Contributions to the

Space Shuttle Program

The NSS programs agreed to provide

some of the key capabilities that the

Space Shuttle Program would need to

achieve all of its goals. As the executive

agent for DoD space, the USAF funded

and managed these programs.

One of these programs, eventually

known as the Inertial Upper Stage,

focused on an upper stage that would

take a spacecraft from the shuttle in

low-Earth orbit to its final mission orbit

or onto an escape trajectory for an

interplanetary mission. Another was a

West Coast launch site for the shuttle,

Vandenberg Air Force Base, California.

Launching from this site would allow

the shuttle to reach high inclination

orbits over the Earth’s poles. Although

almost complete, it was closed after the

Challenger accident in 1986 and much

of the equipment was disassembled and

shipped to KSC to improve or expand

its facilities. Another program was a

USAF shuttle flight operation center in

Colorado. This was intended to be the

mission control center for NSS shuttle

flights, easing the workload on the

control center in Houston, Texas, for

these classified missions. USAF built

the facility and their personnel trained

at Johnson Space Center; however,

when the decision was made to

remove NSS missions from the shuttle

manifest after the Challenger accident,

the facility was not needed for shuttle

flights and eventually it was used for

other purposes.

The Historical Legacy

Page 45

Space Shuttle Enterprise on Space Launch Complex 6 during pad checkout tests at Vandenberg

Air Force Base in 1985. Enterprise was the Orbiter built for the Approach and Landing Tests to prove

flightworthiness. It never became part of the shuttle fleet.

Flying National Security Space

Payloads on the Shuttle

The NSS program leadership matured

during a period when spacecraft and

their ground systems were fairly simple

and orbital operations were not very

complex. In the early 1980s, one

senior NSS program director was often

heard to say, “All operations needs is

a roll of quarters and a phone booth.”

This was hyperbole, but the point was

clear: planning and preparing for orbital

operations was not a priority. It wasn’t

unheard of for an NSS program with

budget, schedule, or political pressures

to launch a new spacecraft before all

the details for how to operate the

spacecraft on orbit had been completely

worked out.

Early on, NASA flight operations

personnel were stunned to see that the

ground systems involved in operating

the most critical NSS spacecraft were

at least a decade behind equivalent

NASA systems. Some even voiced

concern that, because the NSS systems

were so antiquated, they weren’t sure

the NSS spacecraft could be operated

safely with the shuttle. In NASA,

flight operations was a major

organizational focus and had been

since the days of Project Mercury.

NASA flight operations leaders such

as John O’Neil, Jay Honeycutt, Cliff

Charlesworth, and Gene Kranz had an

important voice in how the Space

Shuttle Program allocated its resources

and in its development plans. Line

managers in NASA, including Jay

Greene, Ed Fendell, and Hal Beck,

worked closely with the NSS flight

operations people to merge NSS

spacecraft and shuttle operations

into one seamless activity. Many of

the NASA personnel, especially flight

directors, had no counterpart on the

NSS government team.

To prepare for a mission, NASA flight

operations employed a very thorough

process that focused on ensuring that

flight controllers were ready for

anything the mission might throw at

them. This included practice sessions in

the control centers using spacecraft

simulators that were better than

anything the NSS personnel had seen.

NSS flight operations personnel

thought they had died and gone to

heaven. Here, finally, was an

organization that took “ops” seriously

and committed the resources to do it

right. As the partnership developed,

NASA forced, cajoled, and convinced

the NSS programs to adopt a more

thorough approach to the shuttle

integration and operations readiness

processes. Over time, NASA’s approach

caught on within the NSS. It was

simply a best practice worth emulating.

Another component of NASA human

spaceflight—the role of the

astronaut—was initially very foreign

to NSS personnel. Astronauts tended to

place a very personal stamp on the

plans for “their” mission, which came

as a shock to NSS program personnel.

Some NSS personnel chafed at the

effort required to satisfy the crew

member working with their payload.

On early missions, the commander

or other senior crew members would

not start working with the payload

until the last 6 months or so prior to

launch and would want to make

changes in the plans. This caused some

friction. The NSS people did not want

to deal with last-minute changes so

close to launch. After a few missions,

as the relationship developed,

adjustments were made by both sides

to ease this “last-minute effect.”

1982-1992: National

Security Space

and NASA Complete

11 Missions

The first National Security Space (NSS)

payload was launched on Space

Transportation System (STS)-4 in June

1982. This attached payload (one that

never left the payload bay), called

“82-1,” carried the US Air Force

(USAF) Space Test Program Cryogenic

Infrared Radiance Instrumentation for

Shuttle (CIRRIS) telescope and several

other small experiments. This mission

was originally scheduled for the 18th

shuttle flight; but, as the Space Shuttle

Program slipped, NSS program

management was able to maintain its

schedule and was ready for integration

into the shuttle early in 1982. Since the

first two shuttle missions had gone so

well, NASA decided to allow the 82-1

payload to fly on this flight test mission

despite the conflicts this decision would

cause with the mission’s test goals.

This rather selfless act on the part of

NASA was characteristic of the positive

relationship between NASA and the

NSS programs once the shuttle began

to fly. For the NSS programs, a major

purpose of this mission was to be a

pathfinder for subsequent NSS missions.

This payload was controlled from the

Sunnyvale USAF station in California.

This was also the only NSS mission

where the NSS flight controllers talked

directly to the shuttle crew.

Operational Missions

The next NSS mission, STS-51C,

occurred January 1985, 2½ years after

STS-4. STS-51C was a classified NSS

mission that included the successful

use of the Inertial Upper Stage. The

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The Historical Legacy

Inertial Upper Stage had experienced

a failure during the launch of the first

NASATracking and Data Relay

Satellite mission on STS-6 in 1983.

The subsequent failure investigation and

redesign had resulted in a long delay in

Inertial Upper Stage missions. With the

problem solved, the shuttle launched

into a 28.5-degree orbit with an altitude

of about 407 km (220 nautical miles).

The first manned spaceflight engineer,

Gary Payton, flew as a payload

specialist on this 3-day mission. This

was also the first use of the “Department

of Defense (DoD) Control Mode”—a

specially configured Mission Operations

Control Room at Johnson Space Center

that was designed and equipped with all

the systems required to protect the

classified nature of these missions.

The second and final manned

spaceflight engineer, William Pailes,

flew on the 4-day flight of STS-51J

in October 1985. This shuttle mission

deployed a defense communications

satellite riding on an Inertial Upper

Stage, which took the satellite up to

geosynchronous orbit.

The Challenger and her crew were

lost in a tragic accident the following

January. After launching only three

spacecraft payloads on the first 25

missions, the NSS response to the

Challenger accident was to move all

spacecraft that it could off shuttle

flights. The next NSS spacecraft flew

almost 2 years after the Challenger

accident on the 4-day mission of

STS-27 in December 1988. This

mission was launched into a 57-degree

orbit and had an all-NASA crew, as did

the subsequent NSS spacecraft payload

missions with only one exception

(STS-44 [1991]). No other details on

the STS-27 mission have been released.

The launch rate picked up 8 months

later with the launch of STS-28 in

August and STS-33 in November

(both in 1989), followed by STS-36

in February and STS-38 in November

(both in 1990). The details of these

missions remain classified, but the

rapid launch rate—four missions in

15 months—was working off the

backlog that had built up during the

delays after the Challenger accident.

This pace also demonstrated the

growing maturity of the NSS/NASA

working relationship.

In April 1991, in a departure from the

NSS unified approach to classification

of its activities on the shuttle, the USAF

Space Test Program AFP-675 with the

CIRRIS telescope was launched on

STS-39. This was the first time in the

NSS/NASA relationship that the details

of a dedicated DoD payload were

released to the world prior to launch.

The focus of this mission was Strategic

Defense Initiative research into sensor

designs and environmental phenomena.

The details of this flight and STS-44 in

November 1991 were released to the

public. Their payloads were from

previously publicized USAF programs.

STS-44 crew members included an

Army payload specialist, Tom Hennan.

This mission marked the end of flights

on the shuttle for non-NASA military

payload specialists. Ironically, Warrant

Officer Hennan performed experiments

called “Military Man in Space.” The

spacecraft launched on this mission was

the USAF Defense Support Program

satellite designed to detect nuclear

detonations, missile launches, and

space launches from geosynchronous

orbit. This satellite program had been

in existence for over 20 years. The

satellite launched on STS-44 replaced

an older satellite in the operational

Defense Support Program constellation.

Space Test Program

Another series of experiments, called

“M88-1,” on STS-44 was announced

as an ongoing series of tri-service

experiments designed to assess man’s

visual and communication capabilities

from space. The objectives of M88-1

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overlapped those done by Hennan

with his experiments; however, NASA

Mission Specialist Mario Runco and

the rest of the NASA crew performed

the M88-1 experiments. This activity

used a digital camera to produce

images that could be evaluated on

orbit. Observations were to be radioed

to tactical field users seconds after

the observation pass was complete.

Emphasis was on coordinating

observations with ongoing DoD

exercises to fully assess the military

benefits of a spaceborne observer.

The policy implications of using NASA

astronauts to provide input directly to

military forces on the ground during

shuttle missions have long been

debated. This flight and the following

mission (STS-53) are the only

acknowledged examples of this policy.

A year later in December 1992,

STS-53 was launched with a classified

payload called “DoD-1” on a 7-day

mission. Marty Faga, assistant secretary

of the USAF (space), said: “STS-53

marks a milestone in our long and

productive partnership with NASA.

We have enjoyed outstanding support

from the Space Shuttle Program.

Although this is the last dedicated

shuttle payload, we look forward to

continued involvement with the program

with DoD secondary payloads.”

With the landing of STS-53 at

Kennedy Space Center, the NSS/NASA

partnership came to an end. During

the 10 years of shuttle missions,

11 of the 52 missions were dedicated

to NSS programs. The end of

NSS-dedicated shuttle missions

resulted from the rising costs of shuttle

missions and policy decisions made

as a result of the Challenger accident.

There were few NSS-dedicated

missions relative to the enthusiastic

plans laid in the late 1970s; however,

the Space Shuttle Program had a

lasting impact on the NSS programs.

While the number of NSS-dedicated

missions was small, the partnership

between the NSS programs and NASA

had a lasting impact.

Gary Payton, US Air Force (USAF) Lieutenant

General (retired), flew on STS-51C (1985) as a

payload specialist. He was part of the USAF

manned spaceflight engineering program and

served as USAF Deputy Under Secretary for

Special Programs.

Defense Support Program spacecraft and attached

Inertial Upper Stage prior to release from Atlantis

on STS-44 (1991). This spacecraft provides warning

of ballistic missile attacks on the United States.

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The Historical Legacy

Michael Griffin, PhD

Deputy for technology at the Strategic

Defense Initiative Organization

(1986-1991).

NASA administrator (2005-2009).

Strategic Defense

Initiative Test

“STS-39 was a very complex

mission that led to breakthroughs

in America’s understanding

of the characteristics of missile

signatures in space. The data

we gathered enhanced our ability

to identify and protect ourselves

from future missile threats.

This is one of the most under-

recognized achievements of the

shuttle era.”

STS-39’s Air Force Program-675

equipment mounted on the

experiment support system pallet

in Discovery’s payload bay.

View of the Aurora Australis—or Southern

Lights—taken by Air Force Program-675

Uniformly Redundant Array and Cryogenic

Infrared Radiance Instrumentation during

STS-39 (1991). One of the equipment’s

objectives was to gather data on the Earth’s

aurora, limb, and airglow.

Legacy of the Space

Shuttle Program

and National

Security Space

The greatest legacy of the

NASA/National Security Space

(NSS) partnership was at the personal

level for NSS engineers and managers.

Working on the Space Shuttle

Program in the early 1980s was

exciting and provided just the sort

of motivation that could fuel a career.

NSS personnel learned new and

different operational and engineering

techniques through direct contact

with their NASA counterparts. As a

result, engineering and operations

practices developed by NASA were

applied to the future complex NSS

programs with great success.

Another significant legacy is that

of leadership in the NSS programs.

The manned spaceflight engineer

program in particular was adept at

selecting young officers with potential

to be future leaders of the NSS

programs. A few examples of current

or recent NSS leaders who spent

their formative years in the manned

spaceflight engineer program include:

Gary Payton, Mike Hamel, Jim Armor,

Kathy Roberts, and Larry James.

Others, such as Willie Shelton, were

US Air Force (USAF) flight controllers

assigned to work in Houston, Texas.

Many military personnel working

with NASA returned to the NSS space

programs, providing outstanding

leadership to future programs. Several

ex-astronauts, such as Bob Stuart, John

Fabian, and Kevin Chilton, have held

or are now holding senior leadership

roles in their respective services.

The role that the NASA/NSS

collaboration played in the formation

of Space Command also left a legacy.

While the formation of the USAF

Space Command occurred late in the

NASA/NSS relationship, close contact

between the NSS programs and the

shuttle organizations motivated the

Department of Defense to create an

organization that would have the

organizational clout and budget to deal

with the Space Shuttle Program on a

more equal basis.

The impact on mission assurance and

the rigor in operations planning and

The Historical Legacy

Page 49

preparation could be the most

significant technical legacy the Space

Shuttle Program left the NSS programs.

NASA required participation by the

NSS spacecraft operators in the early

stages of each mission’s planning.

NSS operations personnel quickly

realized that this early involvement

resulted in improved operations

or survivability and provided the

tools and experience necessary

to deal with the new, more complex

NSS spacecraft.

The impact of the Space Shuttle

Program on the NSS cannot be judged

by the small number of NSS-dedicated

shuttle missions. The policy decision

that moved all NSS spacecraft onto

the shuttle formed a team out of the

most creative engineering minds in the

country. There was friction between

the two organizations, but ultimately

it was the people on this NSS/NASA

team who made it work. It is

unfortunate that, as a result of the

Challenger accident, the end of the

partnership came so soon. The success

of this partnership should be measured

not by the number of missions or

even by the data collected, but rather

by the lasting impact on the NSS

programs’ personnel and the

experiences they brought to future

NSS programs.

US Air Force Space Test Program—

Pathfinder for Department of Defense Space Systems

The US Air Force (USAF) Space Test Program was

established as a multiuser space program whose

role is to be the primary provider of spaceflight

for the entire Department of Defense (DoD)

space research community. From

as early as STS-4 (1982), the USAF Space Test

Program used the shuttle to fly payloads relevant

to the military. The goal of the program was to

exploit the use of the shuttle as a research and

development laboratory. In addition to supplying

the primary payloads on several DoD-dedicated

missions, more than 250 secondary payloads

and experiments flew on 95 shuttle missions.

Space Test Program payloads flew in the shuttle

middeck, cargo bay, Spacelab, and Spacehab,

and on the Russian space station Mir during the

Shuttle-Mir missions in the mid 1990s.

A Department of Defense pico-satellite known as Atmospheric Neutral Density

Experiment (ANDE) is released from the STS-116 (2006) payload bay. ANDE consists

of two micro-satellites that measure the density and composition of the low-Earth

orbit atmosphere while being tracked from the ground. The data are used to better

predict the movement of objects in orbit.

Another Legacy:

Relationship with

USSR and Its Allies

In 1972, with the US announcement

of the Space Shuttle as its primary

space transportation system, the

USSR quickly adapted to keep pace.

“Believing the Space Shuttle to be a

military threat to the Soviet Union,

officials of the USSR Ministry of

Defense found little interest in lunar

bases or giant space stations. What

they wanted was a parallel deterrent

to the shuttle.” Premier Leonid

Brezhnev, Russian sources reported,

was particularly distraught at the

thought of a winged spacecraft on an

apparently routine mission in space

suddenly swooping down on Moscow

and delivering an unthinkably

dangerous cargo.

Russian design bureaus offered a

number of innovative counter-

capabilities, but Brezhnev and the

Ministry of Defense were adamant that

a near match was vital. They may not

have known what the American

military was planning with the shuttle,

but they wanted to be prepared for

exactly what it might be. The Soviets

were perplexed by the decision to

go forward with the Space Shuttle.

Their estimates of cost-performance,

particularly over their own

mass-produced space launch vehicles,

were very high. It seemed to make little

practical sense until the announcement

that a military shuttle launch facility

at Vandenberg Air Force Base was

planned; according to one Soviet space

scientist, “… trajectories from

Vandenberg allowed an overflight of

the main centers of the USSR on

the first orbit. So our hypothesis was

that the development of the shuttle

was mainly for military purposes.”

It was estimated that a military payload

could reenter Earth’s atmosphere from

orbit and engage any target within the

USSR in 3 to 4 minutes—much faster

than the anticipated 10 minutes from

launch to detonation by US nuclear

submarines stationed off Arctic

coastlines. This drastically changed the

deterrence calculations of top Soviet

decision makers.

Indeed, deterrence was the great

game of the Cold War. Each side had

amassed nuclear arsenals sufficient

to destroy the other side many times

over, and any threat to the precarious

balance of terror the two sides had

achieved was sure to spell doom.

The key to stability was the capacity

to deny any gain from a surprise or

first strike. A guaranteed response in

the form of a devastating counterattack

was the hole card in this international

game of bluff and brinksmanship.

Any development that threatened to

mitigate a full second strike was a

menace of the highest order.

Several treaties had been signed

limiting or barring various anti-satellite

activities, especially those targeted

against nuclear launch detection

capabilities (in a brute attempt to blind

the second-strike capacity of the other

side). The shuttle, with its robotic arm

used for retrieving satellites in orbit,

could act as an anti-satellite weapon in

a crisis, expensive and dangerous as its

use might be. Thus, the shuttle could

get around prohibitions against

anti-satellite capabilities through its

public image as a peaceful NASA space

plane. So concerned were the Soviets

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The Historical Legacy

with the potential capability of the

shuttle, they developed designs for at

least two orbiting “laser-equipped battle

stations” as a counter and conducted

more than 20 “test launches” of a

massive ground-launched anti-satellite

weapon in the 1970s and 1980s.

In the 1978-1979 strategic arms

limitation talks, the Soviets asked for

a guarantee that the shuttle would not

be used for anti-satellite purposes.

The United States refused. In 1983,

the USSR offered to prohibit the

stationing of any weapons in space,

if the United States would agree.

The catch was the shuttle could not

be used for military activities.

In exchange, the Soviets would

likewise limit the Mir space station

from military interaction—an

untenable exchange.

So a shuttle-equivalent space plane

was bulldozed through the Soviet

budget and the result was the

Buran/Energiya shuttle and heavy-lift

booster. After more than a decade of

funding—and, for the cash-strapped

Soviet government, a crippling

budget—the unmanned Buran debuted

and flew two orbits before landing

flawlessly in November 1988.

Immediately after the impressive

proof-of-concept flight, the Soviets

mothballed Buran.

James Moltz, professor of national

security at the Naval Postgraduate

School, commented that the

“self-inflicted extreme cost of the

Buran/Energiya program did more

to destabilize the Soviet economy

than any response to the Reagan

administration’s efforts in the 1980s.”

If so, the Space Shuttle can be given

at least partial credit for winning

the Cold War.

The Historical Legacy

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Buran/Energiya shuttle and heavy-lift booster, built by the USSR, flew once—uncrewed—in 1988.

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