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The Marshall Star

The headshot image of Lee Mohon

Lee Mohon

Jul 29, 2015
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In This Week’s Star

NASA’s Space Launch System Design ‘Right on Track’ for Journey to Mars

NASA's Space Launch System Program Manager Todd May and others.
NASA’s Space Launch System Program Manager Todd May and others on the critical design review team pore over hundreds of design and development documents on the SLS Block 1 configuration. The critical design review provides a final look at the design and development of the integrated rocket ahead of full-scale fabrication. SLS will be the most powerful rocket ever built for deep space missions, including to an asteroid and ultimately Mars. Credits: NASA/MSFC

You know the feeling of pride and achievement when you’ve worked really hard on a term paper, and finally turn it in? That’s how the critical design review team for NASA’s Space Launch System is feeling this week as the program completed its review.

The in-depth review — the first in almost 40 years for a NASA exploration class vehicle — provides a final look at the design and development of the integrated rocket before full-scale fabrication begins. Throughout the course of 11 weeks, 13 teams — including representatives from several NASA field centers — reviewed more than 1,000 files of data as part of the comprehensive assessment process. 

SLS will be the most powerful rocket ever built for a new era of exploration to destinations beyond Earth’s orbit. It will launch astronauts in the agency’s Orion spacecraft on missions to an asteroid placed in lunar orbit, and eventually to Mars.

“Now that we’ve completed our review, we will brief NASA leadership, along with the independent review team, about the results and readiness to proceed to the next phase. After that step is complete, we’ll move on to design certification,” said Todd May, SLS program manager at NASA’s Marshall Space Flight Center. “Critical design review represents a major commitment by the agency to human exploration, and through these reviews, we ensure the SLS design is on track to being a safe, sustainable and evolvable launch vehicle that will meet the agency’s goals and missions.

The critical design review team.
The critical design review team, including members of the Standing Review Board, listen to presentations during the SLS critical design review. This week, the SLS Program completed its critical design review — a first in almost 40 years for a NASA exploration class vehicle. SLS Program managers will present the results from the critical design review board and Standing Review Board to Marshall’s Center Management Council. After receiving the council’s concurrence, the results then will be briefed to the Human Exploration and Operations Mission Directorate at NASA Headquarters. Credits: NASA/MSFC

“It’s an exciting time for NASA and our nation,” May continued, “as we prepare to go to places in deep space that we’ve never been before.”

The critical design review is for the first of three configurations planned for SLS, referred to as SLS Block 1. It will stand 322 feet tall, provide 8.4 million pounds of thrust at liftoff, weigh 5.5 million pounds and carry 70 metric tons or 154,000 pounds of payload, equivalent to approximately 77 one-ton pickup trucks’ worth of cargo. Its first mission — Exploration Mission-1 — will launch an uncrewed Orion spacecraft to demonstrate the integrated system performance of the SLS rocket and Orion spacecraft before a crewed flight.

Block 1 requires many critical parts to get it off the ground and safely into space, including twin solid rocket boosters, powerful engines, flight computers, avionics and the core stage. The core stage, towering more than 200 feet tall with a diameter of 27.6 feet, will carry cryogenic liquid hydrogen and liquid oxygen that will feed the vehicle’s four RS-25 engines.

The team turned in its work to a Standing Review Board composed of seasoned experts from NASA and industry who are independent of the program. The board will review and assess the program’s readiness and confirm it remains on target to meet the established schedule and cost goals.

“Much of the benefit of this review is what we do to prepare for it because that’s where we really bring things out,” said Jim Reuter, head of the Standing Review Board. “And you can tell it in the spirit of the people here. They are excited about what they’re doing. They can see that this is the review that’s going to make it real.”

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Construction ‘Fueling’ Up for SLS Core Stage Hydrogen Tank

Gore Weld Tool at NASA's Michoud Assembly Facility
A Boeing weld technician inspects a recent weld on the Gore Weld Tool at NASA’s Michoud Assembly Facility in New Orleans. The Gore Weld Tool is used to perform vertical conventional friction-stir welds in the production of gore assemblies for NASA’s Space Launch System core stage hydrogen fuel tank — currently under construction at Michoud. All of the hardware necessary for building the tank that will be used on the first flight of SLS has been delivered to the facility and is awaiting assembly. SLS will be the most powerful rocket ever built for deep space missions, including to an asteroid and ultimately to Mars. The core stage, towering more than 200 feet, will store cryogenic liquid hydrogen and liquid oxygen that will feed the vehicle’s RS-25 engines. Boeing is the prime contractor for the SLS core stage, including avionics. Credits: Boeing
Gore panels
Gore panels, provided to Boeing by supplier MT Aerospace of Germany, are stacked and ready for welding on the Gore Weld Tool at NASA’s Michoud Assembly Facility in New Orleans. Gore panels are preformed aluminum alloy dome segments. They are welded together to form a dome — the end cap to NASA’s Space Launch System core stage hydrogen fuel tank. All of the hardware necessary for building the tank that will be used on the first flight of SLS has been delivered to the facility and is awaiting assembly. SLS will be the most powerful rocket ever built for deep space missions, including to an asteroid and ultimately to Mars. The core stage, towering more than 200 feet, will store cryogenic liquid hydrogen and liquid oxygen that will feed the vehicle’s RS-25 engines. Boeing is the prime contractor for the SLS core stage, including avionics. Credits: Boeing
Circumferential Dome Weld Tool for welding to the dome and a ring
Boeing technicians use cranes and specially designed lift fixtures to move a dome cap onto the Circumferential Dome Weld Tool for welding to the dome and a ring, forming a completed end cap for NASA’s Space Launch System core stage hydrogen fuel tank. All of the hardware necessary for building the tank that will be used on the first flight of SLS has been delivered to the facility and is awaiting assembly. SLS will be the most powerful rocket ever built for deep space missions, including to an asteroid and ultimately to Mars. The core stage, towering more than 200 feet, will store cryogenic liquid hydrogen and liquid oxygen that will feed the vehicle’s RS-25 engines. Boeing is the prime contractor for the SLS core stage, including avionics. Credits: Boeing

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Aft Segment Cast for Second SLS Booster Qualification Test

The aft segment for a full-scale version of a five-segment solid rocket booster
The aft segment for a full-scale version of a five-segment solid rocket booster for NASA’s Space Launch System has been cast at Orbital ATK’s facility in Promontory, Utah. SLS will be the most powerful rocket ever built for deep space missions, including to an asteroid and ultimately to Mars. The aft segment will eventually be integrated with the other four booster segments for a second booster qualification test, scheduled for 2016. The first SLS qualification test for the booster was successfully completed March 11 at Orbital ATK. The second test will support qualification by specifically assessing performance at the cooler end of the motor’s accepted propellant temperature range. After qualification is complete, the boosters will then be ready to proceed toward the first flight of SLS. Orbital ATK is the prime contractor for the boosters. Learn more about the boosters here. Credits: Orbital ATK

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Marshall Center Hosts Mentor-Protégé Agreement Signings Between Teledyne Brown Engineering and Two Universities

By Kenneth Kesner

Photo signing mentor-protégé agreements on July 27.
Marshall, Teledyne Brown, Alabama State University and the University of Nevada, Las Vegas, representatives sign mentor-protégé agreements July 27. At the table are, from left, Leon Wilson, ASU; Nancy Rapoport, UNLV; Marshall Deputy Director Teresa Vanhooser, and Jan Hess, Teledyne Brown; standing are Marshall’s David Brock, left, and David Iosco. Credits: NASA/MSFC/Fred Deaton

NASA mentor-protégé agreements between Teledyne Brown Engineering of Huntsville and two universities — Alabama State University of Montgomery, and the University of Nevada, Las Vegas — were signed during ceremonies July 27 at NASA’s Marshall Space Flight Center.

Both agreements are under Teledyne’s NASA Mission Operations and Integration Contract. Universities and students participating in this program will receive assistance in developing multimedia training for International Space Station Payload Ground Support Personnel and Payload Developers.

“Today’s signings are part of a long Marshall Center tradition of collaboration with industry and universities,” said Teresa Vanhooser, deputy director of Marshall. “We tend to think of mentoring as a one-on-one relationship that helps develop an individual. But groups like these also benefit tremendously from the mentor-protégé relationship and end up gaining from each other.”

Other speakers at the ceremony included Kim Whitson, director of Marshall’s Office of Procurement; David Brock, Marshall’s small business specialist; Jan Hess, president of Teledyne Brown Engineering; Dwight Mosby and Nicole Pelfrey, both of Teledyne Brown; Leon Wilson of Alabama State University; Nancy Rapoport and Zachary Miles of the University of Nevada, Las Vegas; and Mary Traweek, Marshall’s Mission Operations and Integration Contract Office representative.

The 12-month agreement between Teledyne Brown Engineering and Alabama State University is the fifth such agreement between a Marshall prime contractor and a Historically Black College and University. The 12-month agreement with the University of Nevada, Las Vegas, is the first such agreement between a Marshall prime contractor and a Minority-Serving Institution.

The NASA Mentor-Protégé Program was established in 2008 by NASA’s Office of Small Business Programs. It allows NASA prime contractors opportunities to enter into agreements with small businesses and historically black colleges and universities/minority serving institutions under their subcontracting programs, to establish long-term relationships, enhance technical capabilities and enable protégés to successfully compete for larger, more complex prime contract and subcontract awards. Marshall oversaw NASA’s first Mentor-Protégé signing agreement in February 2008.

Kesner, an ASRC Federal/Analytical Services employee, supports the Office of Strategic Analysis & Communications.

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NASA Honors 13 Marshall Team Members with Silver Snoopy Award

On July 28, 13 Marshall Space Flight Center team members were honored with NASA’s Silver Snoopy award for their outstanding achievements related to human flight safety and mission success. The award is presented personally by NASA astronauts, as it represents the astronauts’ own recognition of excellence. Astronaut Michael Barratt and Marshall Director Patrick Scheuermann took part in the presentations. For more information on the award, visit here.

Silver Snoopy Awardees
From left, honorees Bruce K. Wallace, April J. Rivera, Nick J. Hensley, Bryan K. Walls, Zachary H. Taylor and William Vann Bradford are presented NASA’s Silver Snoopy awards by astronaut Michael Barratt, center, for their outstanding achievements related to human flight safety or mission success. Credits: NASA/MSFC/Fred Deaton
Silver Snoopy Awardees
From left, honorees Calvin D. Collins, Donnie R. McCaghren, James Brandon Felts, Susan B. Gardner, Michelle R. Murata, Samuel E. Stephens and Joel W. Robinson are presented NASA’s Silver Snoopy awards by astronaut Michael Barratt, center, for their outstanding achievements related to human flight safety or mission success. Credits: NASA/MSFC/Fred Deaton

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Astronaut Butch Wilmore Shares Excitement of Space Station Life with Marshall Center

NASA astronaut Barry “Butch” Wilmore
NASA astronaut Barry “Butch” Wilmore visited Marshall on July 27 to meet many of the people who made his six-month mission to the International Space Station a success. Wilmore, who is a native of Tennessee, served as the commander for Expedition 42. He gave an overview of the research activities he performed in orbit. Some of the highlights he presented to those gathered in Morris Auditorium included the deployment of satellites via an airlock and helping create the first 3-D printed items ever made in orbit, which are being tested here at Marshall. His spacewalks with fellow astronaut Reid Wiseman were a personal highlight for the veteran pilot and astronaut. Wilmore explained the many changes his body went through during his long stay in the orbiting laboratory and addressed recovering after spending six months away from Earth’s gravity. He also took questions from the audience, which included a group of students from Space Camp at the U.S. Space and Rocket Center. Credits: NASA/MSFC/Fred Deaton

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NASA Associate Administrator Lightfoot Keynotes Marshall Association Luncheon

NASA Associate Administrator Robert Lightfoot
NASA Associate Administrator Robert Lightfoot shared his personal reflections on leadership with Marshall Association members and guests during a luncheon July 28 at NASA’s Marshall Space Flight Center. The Marshall Association is a professional, employee service organization, which includes Marshall team members and retirees. Credits: NASA/MSFC/Emmett Given

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Russellville, Alabama, Rocket Team Wins International Challenge; Tours Marshall

The Engineering Rocket Team from Russellville City Schools
The Engineering Rocket Team from Russellville City Schools, in northwestern Alabama, visited NASA’s Marshall Space Flight Center June 28 as reward for recently winning first place in the International Rocketry Challenge. The challenge, held in June during the 2015 Paris Air Show in France, is the final stage in a series of global competitions requiring student teams to design, build and launch model rockets. The Russellville team won first place in both the flight competition and the presentation of their two-stage rocket design. Their rocket reached an altitude of 824 feet, traveling 200 mph and safely returned its payload to the ground at 14 mph using a parachute recovery system. From the top, team members are Evan Swinney, Cristian Ruiz, Cady Studdard, Katie Burns, Chelsea Suddith, Niles Butts and Andrew Heath. Mark Keeton and Joseph Cole, not pictured, are their coaches. Credits: NASA/MSFC/Charles Beason

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Marshall Hosts Advanced Rocketry Workshop for Student Teams

Fred Kepner, an education specialist in the Academic Affairs Office of NASA’s Marshall Space Flight Center
Fred Kepner, center, education specialist in the Academic Affairs Office of NASA’s Marshall Space Flight Center, discusses proper fin placement on model rockets with teachers attending a July 22-25 advanced rocketry workshop. The workshop, hosted by Marshall, was attended by teams that placed in the top 25 of the Team America Rocketry Challenge — an extra-curricular, project-based learning program modeled around the design, fabrication and testing processes in the aerospace industry. The 13 participants attending represented 11 middle and high schools, plus one youth group organization, from nine states and the U.S. Virgin Islands. Attendees worked side-by-side with Marshall team members during hands-on activities, presentations and facility tours, all to improve their development of high-powered rockets, payloads and NASA Education’s goals and objectives. The workshop concluded as participants attempted National Association of Rocketry Level 1 certification by launching their newly built rockets in nearby Manchester, Tennessee. The Huntsville Area Rocketry Association provided launch services, while Marshall’s Academic Affairs Office provided workshop content, logistics and training. Credits: NASA/MSFC/Emmett Given

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New Pluto Discoveries and Images Featured On ‘This Week @NASA’

A July 24 update at NASA Headquarters of new images and scientific discoveries from NASA’s New Horizons flyby of the dwarf planet Pluto is featured in the latest edition of “This Week @NASA,” a weekly video program broadcast nationwide on NASA-TV and posted online. 

The images reveal a haze in Pluto’s sunlit atmosphere extending 80 miles above the surface – much higher than expected. Models suggest that the haze forms when ultraviolet sunlight breaks apart methane gas.

Additional imagery shows evidence that exotic ices have flowed – and may still be flowing – across Pluto’s surface, similar to the types of glacial movement found on Earth. This unpredicted sign of present-day geologic activity was detected in Sputnik Planum, an area in the western part of Pluto’s heart-shaped Tombaugh Regio.

Additionally, new compositional data from the spacecraft’s Ralph instrument indicate that the center of Sputnik Planum is rich in nitrogen, carbon monoxide, and methane ices. New Horizons is part of NASA’s New Frontiers program and is managed by NASA’s Marshall Space Flight Center.

View this and previous episodes at “This Week @NASA“ or at https://www.youtube.com/user/NASAtelevision.

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