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NASA NTRS2006

NASA Crew and Cargo Launch Vehicle Development Approach Builds on Lessons from Past and Present Missions

The United States (US) Vision for Space Exploration, announced in January 2004, outlines the National Aeronautics and Space Administration's (NASA) strategic goals and objectives, including retiring the Space Shuttle and replacing it with new space transportation systems for missions to the Moon, Mars, and beyond. The Crew Exploration Vehicle (CEV) that the new human-rated Crew Launch Vehicle (CLV) lofts into space early next decade will initially ferry astronauts to the International Space Station (ISS) Toward the end of the next decade, a heavy-lift Cargo Launch Vehicle (CaLV) will deliver the Earth Departure Stage (EDS) carrying the Lunar Surface Access Module (LSAM) to low-Earth orbit (LEO), where it will rendezvous with the CEV launched on the CLV and return astronauts to the Moon for the first time in over 30 years. This paper outlines how NASA is building these new space transportation systems on a foundation of legacy technical and management knowledge, using extensive experience gained from past and ongoing launch vehicle programs to maximize its design and development approach, with the objective of reducing total life cycle costs through operational efficiencies such as hardware commonality. For example, the CLV in-line configuration is composed of a 5-segment Reusable Solid Rocket Booster (RSRB), which is an upgrade of the current Space Shuttle 4- segment RSRB, and a new upper stage powered by the liquid oxygen/liquid hydrogen (LOX/LH2) J-2X engine, which is an evolution of the J-2 engine that powered the Apollo Program s Saturn V second and third stages in the 1960s and 1970s. The CaLV configuration consists of a propulsion system composed of two 5-segment RSRBs and a 33- foot core stage that will provide the LOX/LED needed for five commercially available RS-68 main engines. The J-2X also will power the EDS. The Exploration Launch Projects, managed by the Exploration Launch Office located at NASA's Marshall Space Flight Center, is leading the design, development, testing, and operations planning for these new space transportation systems. Utilizing a foundation of heritage hardware and management lessons learned mitigates both technical and programmatic risk. Project engineers and managers work closely with the Space Shuttle Program to transition hardware, infrastructure, and workforce assets to the new launch systems, leveraging a wealth of knowledge from Shuffle operations. In addition, NASA and its industry partners have tapped into valuable Apollo databases and are applying corporate wisdom conveyed firsthand by Apollo-era veterans of America s original Moon missions. Learning from its successes and failures, NASA employs rigorous systems engineering and systems management processes and principles in a disciplined, integrated fashion to further improve the probability of mission success.

Dumbacher, Daniel L.↗
NASA NTRS2006

NASA Crew and Cargo Launch Vehicle Development Approach Builds on Lessons Learned from Past and Present Missions

A viewgraph presentation of NASA crew and cargo launch vehicle development building upon lessons learned from past and present missions is shown. The topics include: 1) U.S. Vision for Space Exploration; 2) NASA's Exploration Road Map; 3) The Moon-The First Step to Mars and Beyond; 4) Building on a Foundation of Proven Technologies; 5) Constellation Launch Vehicle Elements; 6) 1.5 Launch Earth Orbit/Lunar Orbit Rendezvous; 7) The Journey Continues; 8) Design Philosophy for Mission Success; 9) Lessons Learned: Implementation Tenets; and 10) Lessons Learned: Early Integration with the Operators.

Dumbacher, Dan↗
NASA NTRS2006

NASA Exploration Launch Projects Overview: The Crew Launch Vehicle and the Cargo Launch Vehicle Systems

The U.S. Vision for Space Exploration (January 2004) serves as the foundation for the National Aeronautics and Space Administration's (NASA) strategic goals and objectives. As the NASA Administrator outlined during his confirmation hearing in April 2005, these include: 1) Flying the Space Shuttle as safely as possible until its retirement, not later than 2010. 2) Bringing a new Crew Exploration Vehicle (CEV) into service as soon as possible after Shuttle retirement. 3) Developing a balanced overall program of science, exploration, and aeronautics at NASA, consistent with the redirection of the human space flight program to focus on exploration. 4) Completing the International Space Station (ISS) in a manner consistent with international partner commitments and the needs of human exploration. 5) Encouraging the pursuit of appropriate partnerships with the emerging commercial space sector. 6) Establishing a lunar return program having the maximum possible utility for later missions to Mars and other destinations. In spring 2005, the Agency commissioned a team of aerospace subject matter experts to perform the Exploration Systems Architecture Study (ESAS). The ESAS team performed in-depth evaluations of a number of space transportation architectures and provided recommendations based on their findings? The ESAS analysis focused on a human-rated Crew Launch Vehicle (CLV) for astronaut transport and a heavy lift Cargo Launch Vehicle (CaLV) to carry equipment, materials, and supplies for lunar missions and, later, the first human journeys to Mars. After several months of intense study utilizing safety and reliability, technical performance, budget, and schedule figures of merit in relation to design reference missions, the ESAS design options were unveiled in summer 2005. As part of NASA's systems engineering approach, these point of departure architectures have been refined through trade studies during the ongoing design phase leading to the development phase that begins in 2008. Comprehensive reviews of engineering data and business assessments by both internal and independent reviewers serve as decision gates to ensure that systems can fully meet customer and stakeholder requirements. This paper provides the current CLV and CaLV configuration designs and gives examples of the progress being made during the first year of this significant effort. Safe, reliable, cost-effective space transportation systems are a foundational piece of America s future in space and the next step in realizing the plan for revitalizing lunar capabilities on the passageway to the human exploration of Mars. While building on legacy knowledge and heritage hardware for risk reduction, NASA will apply lessons learned from developing these new launch vehicles to the growth path for future missions. The elements for mission success and continued U.S. leadership in space have been assembled over the past year. As NASA designs and develops these two new systems over the next dozen years, visible progress, such as that reported in this paper, may sustain the national will to stay the course across political administrations and weather the inevitable trials that will be experienced during this challenging endeavor.

Snoddy, Jimmy R.↗
NASA NTRS2006

RS-25 for the NASA Cargo Launch Vehicle: The Evolution of SSME for Space Exploration

A key element of the National Vision for Space Exploration is the development of a heavy-lift Cargo Launch Vehicle (CaLV). Missions to the Moon, Mars, and beyond are only possible with the logistical capacity of putting large payloads in low-earth orbit. However, beyond simple logistics, there exists the need for this capability to be as cost effective as possible to ensure mission sustainability. An element of the CaLV project is, therefore, the development of the RS-25, which represents the evolution of the proven Space Shuttle Main Engine (SSME) into a high-performance, cost-effective expendable rocket engine. The development of the RS-25 will be built upon the foundation of over one million seconds of accumulated hot-fire time on the SSME. Yet in order to transform the reusable SSME into the more cost-effective, expendable RS-25 changes will have to be made. Thus the project will inevitably strive to maintain a balance between demonstrated heritage products and processes and the utilization of newer technology developments. Towards that end, the Core Stage Engine Office has been established at the NASA Marshall Space Flight Center to initiate the design and development of the RS-25 engine. This paper is being written very early in the formulation phase of the RS-25 project. Therefore the focus of this paper will be to present the scope, challenges, and opportunities for the RS-25 project. Early schedules and development decisions and plans will be explained. For not only must the RS-25 project achieve cost effectiveness through the development of new, evolved components such as a channel-wall nozzle, a new HIP-bonded main combustion chamber, and several others, it must simultaneously develop the means whereby this engine can be manufactured on a scale never envisioned for the SSME. Thus, while the overall project will span the next eight to ten years, there is little doubt that even this schedule is aggressive with a great deal of work to accomplish.

Kynard, Michael H.↗
NASA NTRS2006

A New Heavy-Lift Capability for Space Exploration: NASA's Ares V Cargo Launch Vehicle

The National Aeronautics and Space Administration (NASA) is developing new launch systems in preparation for the retirement of the Space Shuttle by 2010, as directed in the United States (U.S.) Vision for Space Exploration. The Ares I Crew Launch Vehicle (CLV) and the Ares V heavy-lift Cargo Launch Vehicle (CaLV) systems will build upon proven, reliable hardware derived from the Apollo Saturn (1961 to 1975) and Space Shuttle (1972 to 2010) programs to deliver safe, reliable, affordable space transportation solutions. This approach leverages existing aerospace talent and a unique infrastructure, as well as the vast amount of legacy knowledge gained from almost a half-century of hard-won experience in the space enterprise. Beginning early next decade, the Ares I will launch the new Crew Exploration Vehicle (CEV) to the International Space Station (ISS) or to low-Earth orbit for trips to the Moon and, ultimately, Mars. Late next decade, the Ares V's Earth Departure Stage will carry larger payloads such as the lunar lander into orbit, and the Crew Exploration Vehicle will dock with it for missions to the Moon, where astronauts will explore new territories and conduct science and technology experiments. Both the Ares I and Ares V systems are being designed to support longer future trips to Mars. The Exploration Launch Projects Office, located at NASA's Marshall Space Flight Center, is designing, developing, testing, and evaluating both launch vehicle systems in partnership with other NASA Centers, Government agencies, and industry contractors. This paper provides top-level information regarding the genesis and evolution of the baseline configuration for the Ares V heavy-lift system. It also touches on risk-based management strategies, such as building on powerful hardware and promoting common features between the Ares I and Ares V systems to reduce technical, schedule, and cost risks, as well as development and operations costs. Finally, it gives a summary of several notable accomplishments over the past year, since the Exploration Launch Projects effort officially kicked off in October 2005, and looks ahead at work planned for 2007 and beyond.

Sumrall, John P.↗
NASA NTRS2006

Development of the J-2X Engine for the Ares I Crew Launch Vehicle and the Ares V Cargo Launch Vehicle: Building on the Apollo Program for Lunar Return Missions

The United States (U.S.) Vision for Space Exploration directs NASA to develop two new launch vehicles for sending humans to the Moon, Mars, and beyond. In January 2006, NASA streamlined its hardware development approach for replacing the Space Shuttle after it is retired in 2010. Benefits of this approach include reduced programmatic and technical risks and the potential to return to the Moon by 2020, by developing the Ares I Crew Launch Vehicle (CLV) propulsion elements now, with full extensibility to future Ares V Cargo Launch Vehicle (CaLV) lunar systems. This decision was reached after the Exploration Launch Projects Office performed a variety of risk analyses, commonality assessments, and trade studies. The Constellation Program selected the Pratt & Whitney Rocketdyne J-2X engine to power the Ares I Upper Stage Element and the Ares V Earth Departure Stage. This paper narrates the evolution of that decision; describes the performance capabilities expected of the J-2X design, including potential commonality challenges and opportunities between the Ares I and Ares V launch vehicles; and provides a current status of J-2X design, development, and hardware testing activities. This paper also explains how the J-2X engine effort mitigates risk by building on the Apollo Program and other lessons lived to deliver a human-rated engine that is on an aggressive development schedule, with its first demonstration flight in 2012.

Snoddy, Jim↗
NASA NTRS2007

Development of the J-2X Engine for the Ares I Crew Launch Vehicle and the Ares V Cargo Launch Vehicle: Building on the Apollo Program for Lunar Return Missions

The United States (U.S.) Vision for Space Exploration has directed NASA to develop two new launch vehicles for sending humans to the Moon, Mars, and beyond. In January 2006, NASA streamlined its hardware development approach for replacing the Space Shuttle after it is retired in 2010. Benefits of this approach include reduced programmatic and technical risks and the potential to return to the Moon by 2020, by developing the Ares I Crew Launch Vehicle (CLV) propulsion elements now, with full extensibility to future Ares V Cargo Launch Vehicle (CaLV) lunar systems. The Constellation Program selected the Pratt & Whitney Rocketdyne J-2X engine to power the Ares I Upper Stage Element and the Ares V Earth Departure Stage. This decision was reached during the Exploration Systems Architecture Study and confirmed after the Exploration Launch Projects Office performed a variety of risk analyses, commonality assessments, and trade studies. This paper narrates the evolution of that decision; describes the performance capabilities expected of the J-2X design, including potential commonality challenges and opportunities between the Ares I and Ares V launch vehicles; and provides a current status of J-2X design, development, and hardware testing activities. This paper also explains how the J-2X engine effort mitigates risk by testing existing engine hardware and designs; building on the Apollo Program (1961 to 1975), the Space Shuttle Program (1972 to 2010); and consulting with Apollo-era experts to derive other lessons lived to deliver a human-rated engine that is on an aggressive development schedule, with its first demonstration flight in 2012.

Greene, William D.↗
NASA NTRS2007

Development of the J-2X Engine for the Ares I Crew Launch Vehicle and the Ares V Cargo Launch Vehicle: Building on the Apollo Program for Lunar Return Missions

The United States (U.S.) Vision for Space Exploration has directed NASA to develop two new launch vehicles for sending humans to the Moon, Mars, and beyond. In January 2006, NASA streamlined its hardware development approach for replacing the Space Shuttle after it is retired in 2010. Benefits of this approach include reduced programmatic and technical risks and the potential to return to the Moon by 2020 by developing the Ares I Crew Launch Vehicle (CLV) propulsion elements now, with full extensibility to future Ares V Cargo Launch Vehicle (CaLV) lunar systems. The Constellation Program selected the Pratt & Whitney Rocketdyne J-2X engine to power the Ares I Upper Stage Element and the Ares V Earth Departure Stage (EDS). This decision was reached during the Exploration Systems Architecture Study and confirmed after the Exploration Launch Projects Office performed a variety of risk analyses, commonality assessments, and trade studies. This paper narrates the evolution of that decision; describes the performance capabilities expected of the J-2X design, including potential commonality challenges and opportunities between the Ares I and Ares V launch vehicles; and provides a current status of J-2X design, development, and hardware testing activities. This paper also explains how the J-2X engine effort mitigates risk by testing existing engine hardware and designs; building on the Apollo Program (1961 to 1975), the Space Shuttle Program (1972 to 2010); and consulting with Apollo era experts to derive other lessons learned to deliver a human-rated engine that is on an aggressive development schedule, with its first demonstration flight in 2012.

Greene, WIlliam↗
NASA NTRS2007

A New Heavy-Lift Capability for Space Exploration: NASA's Ares V Cargo Launch Vehicle

The National Aeronautics and Space Administration (NASA) is developing new launch systems and preparing to retire the Space Shuttle by 2010, as directed in the United States (U.S.) Vision for Space Exploration. The Ares I Crew Launch Vehicle (CLV) and the Ares V heavy-lift Cargo Launch Vehicle (CaLV) systems will build upon proven, reliable hardware derived from the Apollo-Saturn and Space Shuttle programs to deliver safe, reliable, affordable space transportation solutions. This approach leverages existing aerospace talent and a unique infrastructure, as well as legacy knowledge gained from nearly 50 years' experience developing space hardware. Early next decade, the Ares I will launch the new Orion Crew Exploration Vehicle (CEV) to the International Space Station (ISS) or to low-Earth orbit for trips to the Moon and, ultimately, Mars. Late next decade, the Ares V's Earth Departure Stage will carry larger payloads such as the lunar lander into orbit, and the Crew Exploration Vehicle will dock with it for missions to the Moon, where astronauts will explore new territories and conduct science and technology experiments. Both Ares I and Ares V are being designed to support longer future trips to Mars. The Exploration Launch Projects Office is designing, developing, testing, and evaluating both launch vehicle systems in partnership with other NASA Centers, Government agencies, and industry contractors. This paper provides top-level information regarding the genesis and evolution of the baseline configuration for the Ares V heavy-lift system. It also discusses riskbased, management strategies, such as building on powerful hardware and promoting common features between the Ares I and Ares V systems to reduce technical, schedule, and cost risks, as well as development and operations costs. Finally, it summarizes several notable accomplishments since October 2005, when the Exploration Launch Projects effort officially kicked off, and looks ahead at work planned for 2007 and beyond.

Sumrall, John P.↗
NASA NTRS2007

Progress on the J-2X Upper Stage Engine for the Ares I Crew Launch Vehicle and the Ares V Cargo Launch Vehicle

NASA's Vision for Exploration requires a safe, reliable, affordable upper stage engine to power the Ares I Crew Launch Vehicle (CLV) and the Ares V Cargo Launch Vehicle. The J-2X engine is being developed for that purpose, epitomizing NASA's philosophy of employing legacy knowledge, heritage hardware, and commonality to carry the next generation of explorers into low-Earth orbit and out into the solar system This presentation gives top-level details on accomplishments to date and discusses forward work necessary to bring the J-2X engine to the launch pad.

Byrd, Thomas D.↗
NASA NTRS2008

Cargo Integration Products for External Release

This document consists of a listing of integration products by function: Reconfiguration Engineering, Payload Interface Requirements, and Cargo Integration Analysis. The products may be accessed from, the Flight Operation and Integration Office page, i.e. http://sspweb.jsc.nasa.gov/.

Sills, Joel W.↗
NASA NTRS2008

Refinements in the Design of the Ares V Cargo Launch Vehicle for NASA's, Exploration Strategy

NASA is developing a new launch vehicle fleet to fulfill the national goals of replacing the shuttle fleet, completing the International Space Station (ISS), and exploring the Moon on the way to eventual exploration of Mars and beyond. Programmatic and technical decisions during early architecture studies and subsequent design activities were focused on safe, reliable operationally efficient vehicles that could support a sustainable exploration program. A pair of launch vehicles was selected to support those goals the Ares I crew launch vehicle and the Ares V cargo launch vehicle. They will be the first new human-rated launch vehicles developed by NASA in more than 30 years (Figure 1). Ares I will be the first to fly, beginning space station ferry operations no later than 2015. It will be able to carry up to six astronauts to ISS or support up to four astronauts for expeditions to the moon. Ares V is scheduled to be operational in the 2020 timeframe and will provide the propulsion systems and payload to truly extend human exploration beyond low-Earth orbit. (LEO).

Creech, Steve↗
NASA NTRS2007

Foundation for Heavy Lift: Early Developments in the Ares V Cargo Launch Vehicle

The Ares V Cargo Launch Vehicle (CaLV) is NASA's primary vessel for safe, reliable delivery of the Lunar Surface Access Module (LSAM) and other resources into Earth orbit, as articulated in the U.S. Vision for Space Exploration.' The Ares V launch concept is shown. The foundation for this heavy-lift companion to the Ares I Crew Launch Vehicle (CLV) is taking shape within NASA and with its government and industry partners. This paper will address accomplishments in the Ares V Launch Vehicle during 2006 and 2007 and offer a preview of future activities.

Sumrall, John P.↗
NASA NTRS2007

The First Year in Review: NASA's Ares I Crew Launch Vehicle and Ares V Cargo Launch Vehicle

The U.S. Vision for Space Exploration guides NASA's challenging missions of scientific discovery.' Developing safe, reliable, and affordable space transportation systems for the human and robotic exploration of space is a key component of fulfilling the strategic goals outlined in the Vision, as well as in the U.S. Space Policy. In October 2005, the Exploration Systems Mission Directorate and its Constellation Program chartered the Exploration Launch Projects Office, located at the Marshall Space Flight Center, to design, develop, test, and field a new generation of launch vehicles that would fulfill customer and stakeholder requirements for trips to the Moon, Mars, and beyond. The Ares I crew launch vehicle is slated to loft the Orion crew exploration vehicle to orbit by 2014, while the heavy-lift Ares V cargo launch vehicle will deliver the lunar lander to orbit by 2020 (Fig. 1). These systems are being designed to empower America's return to the Moon to prepare for the first astronaut on Mars. The new launch vehicle designs now under study reflect almost 50 years of hard-won experience gained from the Saturn's missions to the Moon in the late 1960s and early 1970s, and from the venerable Space Shuttle, which is due to be retired by 2010.

Dumbacher, Daniel L.↗
NASA NTRS2007

Developing Primary Propulsion for the Ares I Crew Launch Vehicle and Ares V Cargo Launch Vehicle

In accordance with the U.S. Vision for Space Exploration, NASA has been tasked to send human beings to the moon, Mars, and beyond. The first stage of NASA's new Ares I crew launch vehicle (Figure 1), which will loft the Orion crew exploration vehicle into low-Earth orbit early next decade, will consist of a Space Shuttle-derived five-segment Reusable Solid Rocket Booster (RSRB); a pair of similar RSRBs also will be used on the Ares V cargo launch vehicle's core stage propulsion system. This paper will discuss the basis for choosing this particular propulsion system; describe the activities the Exploration Launch Projects (ELP) Office is engaged in at present to develop the first stage; and offer a preview of future development activities related to the first Ares l integrated test flight, which is planned for 2009.

Priskos, Alex S.↗
NASA NTRS2009

Desktop Application Program to Simulate Cargo-Air-Drop Tests

The DSS Application is a computer program comprising a Windows version of the UNIX-based Decelerator System Simulation (DSS) coupled with an Excel front end. The DSS is an executable code that simulates the dynamics of airdropped cargo from first motion in an aircraft through landing. The bare DSS is difficult to use; the front end makes it easy to use. All inputs to the DSS, control of execution of the DSS, and postprocessing and plotting of outputs are handled in the front end. The front end is graphics-intensive. The Excel software provides the graphical elements without need for additional programming. Categories of input parameters are divided into separate tabbed windows. Pop-up comments describe each parameter. An error-checking software component evaluates combinations of parameters and alerts the user if an error results. Case files can be created from inputs, making it possible to build cases from previous ones. Simulation output is plotted in 16 charts displayed on a separate worksheet, enabling plotting of multiple DSS cases with flight-test data. Variables assigned to each plot can be changed. Selected input parameters can be edited from the plot sheet for quick sensitivity studies.

Cuthbert, Peter↗
NASA NTRS2002

Multi-Purpose Logistics Module (MPLM) Cargo Heat Exchanger

This paper describes the New Shuttle Orbiter's Multi- Purpose Logistics Modulo (MPLM) Cargo Heat Exchanger (HX) and associated MPLM cooling system. This paper presents Heat Exchanger (HX) design and performance characteristics of the system.

Zampiceni, John J.↗