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NASA NTRS2014

NASA's Space Launch System: An Enabling Capability for Discovery

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is making progress toward delivering a new capability for human spaceflight and scientific missions beyond Earth orbit. Developed with the goals of safety, affordability, and sustainability in mind, the SLS rocket will launch the Orion Multi-Purpose Crew Vehicle (MPCV), equipment, supplies, and major science missions for exploration and discovery. Making its first uncrewed test flight in 2017 and its first crewed flight in 2021, the SLS will evolve into the most powerful launch vehicle ever flown, capable of supporting human missions into deep space and to Mars. This paper will summarize the planned capabilities of the vehicle, the progress the SLS Program has made in the years since the Agency formally announced its architecture in September 2011, and the path the program is following to reach the launch pad in 2017 and then to evolve the 70 metric ton (t) initial lift capability to 130 t lift capability. The paper will outline the milestones the program has already reached, from developmental milestones such as the manufacture of the first flight hardware and recordbreaking engine testing, to life-cycle milestones such as the vehicle's Preliminary Design Review in the summer of 2013. The paper will also discuss the remaining challenges in both delivering the 70 t vehicle and in evolving its capabilities to the 130 t vehicle, and how the program plans to accomplish these goals. In addition, this paper will demonstrate how the Space Launch System is being designed to enable or enhance not only human exploration missions, but robotic scientific missions as well. Because of its unique launch capabilities, SLS will support simplifying spacecraft complexity, provide improved mass margins and radiation mitigation, and reduce mission durations. These capabilities offer attractive advantages for ambitious science missions by reducing infrastructure requirements, cost, and schedule. A traditional baseline approach for a mission to investigate the Jovian system would require a complicated trajectory with several gravity-assist planetary fly-bys to achieve the necessary outbound velocity. The SLS rocket, offering significantly higher C3 energies, can more quickly and effectively take the mission directly to its destination, providing scientific results sooner and at lower operational cost. The SLS rocket will launch payloads of unprecedented mass and volume, such as "monolithic" telescopes and in-space infrastructure, and will revolutionize science mission planning and design for years to come. As this paper will explain, SLS is making measurable progress toward becoming a global infrastructure asset for robotic and human scouts of all nations by harnessing business and technological innovations to deliver sustainable solutions for space exploration.

Creech, Stephen D.↗
NASA NTRS2014

NASA's Space Launch System: An Enabling Capability for Discovery

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is making progress toward delivering a new capability for human spaceflight and scientific missions beyond Earth orbit. Developed with the goals of safety, affordability, and sustainability in mind, the SLS rocket will launch the Orion Multi-Purpose Crew Vehicle (MPCV), equipment, supplies, and major science missions for exploration and discovery. Making its first uncrewed test flight in 2017 and its first crewed flight in 2021, the SLS will evolve into the most powerful launch vehicle ever flown, capable of supporting human missions into deep space and to Mars. This paper will summarize the planned capabilities of the vehicle, the progress the SLS Program has made in the years since the Agency formally announced its architecture in September 2011, and the path the program is following to reach the launch pad in 2017 and then to evolve the 70 metric ton (t) initial lift capability to 130 t lift capability. The paper will outline the milestones the program has already reached, from developmental milestones such as the manufacture of the first flight hardware and recordbreaking engine testing, to life-cycle milestones such as the vehicle's Preliminary Design Review in the summer of 2013. The paper will also discuss the remaining challenges in both delivering the 70 t vehicle and in evolving its capabilities to the 130 t vehicle, and how the program plans to accomplish these goals. In addition, this paper will demonstrate how the Space Launch System is being designed to enable or enhance not only human exploration missions, but robotic scientific missions as well. Because of its unique launch capabilities, SLS will support simplifying spacecraft complexity, provide improved mass margins and radiation mitigation, and reduce mission durations. These capabilities offer attractive advantages for ambitious science missions by reducing infrastructure requirements, cost, and schedule. A traditional baseline approach for a mission to investigate the Jovian system would require a complicated trajectory with several gravity-assist planetary fly-bys to achieve the necessary outbound velocity. The SLS rocket, offering significantly higher C3 energies, can more quickly and effectively take the mission directly to its destination, providing scientific results sooner and at lower operational cost. The SLS rocket will launch payloads of unprecedented mass and volume, such as "monolithic" telescopes and in-space infrastructure, and will revolutionize science mission planning and design for years to come. As this paper will explain, SLS is making measurable progress toward becoming a global infrastructure asset for robotic and human scouts of all nations by harnessing business and technological innovations to deliver sustainable solutions for space exploration.

Creech, Stephen D.↗
NASA NTRS2014

The Nuclear Cryogenic Propulsion Stage

Nuclear Thermal Propulsion (NTP) development efforts in the United States have demonstrated the technical viability and performance potential of NTP systems. For example, Project Rover (1955 - 1973) completed 22 high power rocket reactor tests. Peak performances included operating at an average hydrogen exhaust temperature of 2550 K and a peak fuel power density of 5200 MW/m3 (Pewee test), operating at a thrust of 930 kN (Phoebus-2A test), and operating for 62.7 minutes in a single burn (NRX-A6 test). Results from Project Rover indicated that an NTP system with a high thrust-to-weight ratio and a specific impulse greater than 900 s would be feasible. Excellent results were also obtained by the former Soviet Union. Although historical programs had promising results, many factors would affect the development of a 21st century nuclear thermal rocket (NTR). Test facilities built in the US during Project Rover no longer exist. However, advances in analytical techniques, the ability to utilize or adapt existing facilities and infrastructure, and the ability to develop a limited number of new test facilities may enable affordable development, qualification, and utilization of a Nuclear Cryogenic Propulsion Stage (NCPS). Bead-loaded graphite fuel was utilized throughout the Rover/NERVA program, and coated graphite composite fuel (tested in the Nuclear Furnace) and cermet fuel both show potential for even higher performance than that demonstrated in the Rover/NERVA engine tests.. NASA's NCPS project was initiated in October, 2011, with the goal of assessing the affordability and viability of an NCPS. FY 2014 activities are focused on fabrication and test (non-nuclear) of both coated graphite composite fuel elements and cermet fuel elements. Additional activities include developing a pre-conceptual design of the NCPS stage and evaluating affordable strategies for NCPS development, qualification, and utilization. NCPS stage designs are focused on supporting human Mars missions. The NCPS is being designed to readily integrate with the Space Launch System (SLS). A wide range of strategies for enabling affordable NCPS development, qualification, and utilization should be considered. These include multiple test and demonstration strategies (both ground and in-space), multiple potential test sites, and multiple engine designs. Two potential NCPS fuels are currently under consideration - coated graphite composite fuel and tungsten cermet fuel. During 2014 a representative, partial length (approximately 16") coated graphite composite fuel element with prototypic depleted uranium loading is being fabricated at Oak Ridge National Laboratory (ORNL). In addition, a representative, partial length (approximately 16") cermet fuel element with prototypic depleted uranium loading is being fabricated at Marshall Space Flight Center (MSFC). During the development process small samples (approximately 3" length) will be tested in the Compact Fuel Element Environmental Tester (CFEET) at high temperature (approximately 2800 K) in a hydrogen environment to help ensure that basic fuel design and manufacturing process are adequate and have been performed correctly. Once designs and processes have been developed, longer fuel element segments will be fabricated and tested in the Nuclear Thermal Rocket Element Environmental Simulator (NTREE) at high temperature (approximately 2800 K) and in flowing hydrogen.

Houts, Michael G.↗
NASA NTRS2013

Performance Characterization of the Air Force Transformational Satellite 12 kW Hall Thruster

The STMD GCD ISP project is tasked with developing, maturing, and testing enabling human exploration propulsion requirements and potential designs for advanced high-energy, in-space propulsion systems to support deep-space human exploration and reduce travel time between Earth's orbit and future destinations for human activity. High-power Hall propulsion systems have been identified as enabling technologies and have been the focus of the activities at NASA Glenn-In-house effort to evaluate performance and interrogate operation of NASA designed and manufactured Hall thrusters. Evaluate existing high TRL EP devices that may be suitable for implementation in SEP TDM.

Propulsion↗
NASA NTRS2014

Studies of Fission Fragment Rocket Engine Propelled Spacecraft

The NASA Office of Chief Technologist has funded from FY11 through FY14 successive studies of the physics, design, and spacecraft integration of a Fission Fragment Rocket Engine (FFRE) that directly converts the momentum of fission fragments continuously into spacecraft momentum at a theoretical specific impulse above one million seconds. While others have promised future propulsion advances if only you have the patience, the FFRE requires no waiting, no advances in physics and no advances in manufacturing processes. Such an engine unequivocally can create a new era of space exploration that can change spacecraft operation. The NIAC (NASA Institute for Advanced Concepts) Program Phase 1 study of FY11 first investigated how the revolutionary FFRE technology could be integrated into an advanced spacecraft. The FFRE combines existent technologies of low density fissioning dust trapped electrostatically and high field strength superconducting magnets for beam management. By organizing the nuclear core material to permit sufficient mean free path for escape of the fission fragments and by collimating the beam, this study showed the FFRE could convert nuclear power to thrust directly and efficiently at a delivered specific impulse of 527,000 seconds. The FY13 study showed that, without increasing the reactor power, adding a neutral gas to the fission fragment beam significantly increased the FFRE thrust through in a manner analogous to a jet engine afterburner. This frictional interaction of gas and beam resulted in an engine that continuously produced 1000 pound force of thrust at a delivered impulse of 32,000 seconds, thereby reducing the currently studied DRM 5 round trip mission to Mars from 3 years to 260 days. By decreasing the gas addition, this same engine can be tailored for much lower thrust at much higher impulse to match missions to more distant destinations. These studies created host spacecraft concepts configured for manned round trip journeys. While the vehicles are very large, they are primarily made up of a habitat payload on one end, the engine on the opposite end and a connecting spine containing radiator acreage needed to reject the heat of this powerful, but inefficient engine. These studies concluded that the engine and spacecraft are within today's technology, could be built, tested, launched on several SLS launchers, integrated, checked out, maintained at an in-space LEO base, and operated for decades just as Caribbean cruise ships operate today. The nuclear issues were found to be far less daunting that [than for] current nuclear engines. The FFRE produces very small amounts of radioactive efflux compared to their impulse, easily contained in an evacuated "bore-hole" test site. The engine poses no launch risk since it is simply a structure containing no fissionable material. The nuclear fuel is carried to orbit in containers highly crash-proofed for launch accidents from which it, in a liquid medium, is injected into the FFRE. The radioactive exhaust, with a velocity above 300 kilometers per second rapidly leaves the solar system.

Werka, Robert O.↗
NASA NTRS2014

Development of a Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN)

An invention of a new and novel space robotic manipulator is described. By using a combination of lightweight truss links, a novel hinge joint, tendon-articulation and passive tension stiffening, this new robotic manipulator architecture achieves compact packaging, high strength, stiffness and dexterity while being very lightweight compared to conventional manipulators. The manipulator is also very modular; easy to scale for different reach, load and stiffness requirements; enabling customization for a diverse set of applications. Novel features of the new manipulator concept are described as well as some of the approaches to implement these design features. Two diverse applications are presented to show the versatility of the concept. First generation prototype hardware was designed, manufactured and has been assembled into a working manipulator that is being used to refine and extend development efforts.

Doggett, William R.↗
NASA NTRS2015

Evolvable Mars Campaign Long Duration Habitation Strategies: Architectural Approaches to Enable Human Exploration Missions

The Evolvable Mars Campaign (EMC) is the current NASA Mars mission planning effort which seeks to establish sustainable, realistic strategies to enable crewed Mars missions in the mid-2030s timeframe. The primary outcome of the Evolvable Mars Campaign is not to produce "The Plan" for sending humans to Mars, but instead its intent is to inform the Human Exploration and Operations Mission Directorate near-term key decisions and investment priorities to prepare for those types of missions. The FY'15 EMC effort focused upon analysis of integrated mission architectures to identify technically appealing transportation strategies, logistics build-up strategies, and vehicle designs for reaching and exploring Mars moons and Mars surface. As part of the development of this campaign, long duration habitats are required which are capable of supporting crew with limited resupply and crew abort during the Mars transit, Mars moons, and Mars surface segments of EMC missions. In particular, the EMC design team sought to design a single, affordable habitation system whose manufactured units could be outfitted uniquely for each of these missions and reused for multiple crewed missions. This habitat system must provide all of the functionality to safely support 4 crew for long durations while meeting mass and volume constraints for each of the mission segments set by the chosen transportation architecture and propulsion technologies. This paper describes several proposed long-duration habitation strategies to enable the Evolvable Mars Campaign through improvements in mass, cost, and reusability, and presents results of analysis to compare the options and identify promising solutions. The concepts investigated include several monolithic concepts: monolithic clean sheet designs, and concepts which leverage the co-manifested payload capability of NASA's Space Launch System (SLS) to deliver habitable elements within the Universal Payload Adaptor between the SLS upper stage and the Orion/Service module on the top of the vehicle. Multiple modular habitat options for Mars surface and in-space missions are also considered with various functionality and volume splits between modules to find the best balance of reducing the single largest mass which must be delivered to a destination and reducing the number of separate elements which must be launched. Analysis results presented for each of these concepts in this paper include mass/volume/power sizing using parametric sizing tools, identification of unique operational constraints, and limited comments on the additional impacts of reusability/dormancy on system design. Finally, recommendations will be made for promising solutions which will be carried forward for consideration in the Evolvable Mars Campaign work.

Simon, Matthew A.↗
NASA NTRS2016

Developing the World's Most Powerful Solid Booster

NASA's Journey to Mars has begun. Indicative of that challenge, this will be a multi-decadal effort requiring the development of technology, operational capability, and experience. The first steps are underway with more than 15 years of continuous human operations aboard the International Space Station (ISS) and development of commercial cargo and crew transportation capabilities. NASA is making progress on the transportation required for deep space exploration - the Orion crew spacecraft and the Space Launch System (SLS) heavy-lift rocket that will launch Orion and large components such as in-space stages, habitat modules, landers, and other hardware necessary for deep-space operations. SLS is a key enabling capability and is designed to evolve with mission requirements. The initial configuration of SLS - Block 1 - will be capable of launching more than 70 metric tons (t) of payload into low Earth orbit, greater mass than any other launch vehicle in existence. By enhancing the propulsion elements and larger payload fairings, future SLS variants will launch 130 t into space, an unprecedented capability that simplifies hardware design and in-space operations, reduces travel times, and enhances two solid propellant five-segment boosters, both based on space shuttle technologies. This paper will focus on development of the booster, which will provide more than 75 percent of total vehicle thrust at liftoff. Each booster is more than 17 stories tall, 3.6 meters (m) in diameter and weighs 725,000 kilograms (kg). While the SLS booster appears similar to the shuttle booster, it incorporates several changes. The additional propellant segment provides additional booster performance. Parachutes and other hardware associated with recovery operations have been deleted and the booster designated as expendable for affordability reasons. The new motor incorporates new avionics, new propellant grain, asbestos-free case insulation, a redesigned nozzle, streamlined manufacturing processes, and new inspection techniques. New materials and processes provide improved performance, safety, and affordability but also have led to challenges for the government/industry development team. The team completed its first full-size qualification motor test firing in early 2015. The second is scheduled for mid-2016. This paper will discuss booster accomplishments to date, as well as challenges and milestones ahead.

Priskos, Alex S.↗
NASA NTRS2016

NASA's Space Launch System: Developing the World's Most Powerful Solid Booster

NASA's Journey to Mars has begun. Indicative of that challenge, this will be a multi-decadal effort requiring the development of technology, operational capability, and experience. The first steps are under way with more than 15 years of continuous human operations aboard the International Space Station (ISS) and development of commercial cargo and crew transportation capabilities. NASA is making progress on the transportation required for deep space exploration - the Orion crew spacecraft and the Space Launch System (SLS) heavy-lift rocket that will launch Orion and large components such as in-space stages, habitat modules, landers, and other hardware necessary for deep-space operations. SLS is a key enabling capability and is designed to evolve with mission requirements. The initial configuration of SLS - Block 1 - will be capable of launching more than 70 metric tons (t) of payload into low Earth orbit, greater mass than any other launch vehicle in existence. By enhancing the propulsion elements and larger payload fairings, future SLS variants will launch 130 t into space, an unprecedented capability that simplifies hardware design and in-space operations, reduces travel times, and enhances the odds of mission success. SLS will be powered by four liquid fuel RS-25 engines and two solid propellant five-segment boosters, both based on space shuttle technologies. This paper will focus on development of the booster, which will provide more than 75 percent of total vehicle thrust at liftoff. Each booster is more than 17 stories tall, 3.6 meters (m) in diameter and weighs 725,000 kilograms (kg). While the SLS booster appears similar to the shuttle booster, it incorporates several changes. The additional propellant segment provides additional booster performance. Parachutes and other hardware associated with recovery operations have been deleted and the booster designated as expendable for affordability reasons. The new motor incorporates new avionics, new propellant grain, asbestos-free case insulation, a redesigned nozzle, streamlined manufacturing processes, and new inspection techniques. New materials and processes provide improved performance, safety, and affordability but also have led to challenges for the government/industry development team. The team completed its first full-size qualification motor test firing in early 2015. The second is scheduled for mid-2016. This paper will discuss booster accomplishments to date, as well as challenges and milestones ahead.

Priskos, Alex↗
NASA NTRS2016

Cis-Lunar Reusable In-Space Transportation Architecture for the Evolvable Mars Campaign

Human exploration missions to Mars or other destinations in the solar system require large quantities of propellant to enable the transportation of required elements from Earth's sphere of influence to Mars. Current and proposed launch vehicles are incapable of launching all of the requisite mass on a single vehicle; hence, multiple launches and in-space aggregation are required to perform a Mars mission. This study examines the potential of reusable chemical propulsion stages based in cis-lunar space to meet the transportation objectives of the Evolvable Mars Campaign and identifies cis-lunar propellant supply requirements. These stages could be supplied with fuel and oxidizer delivered to cis-lunar space, either launched from Earth or other inner solar system sources such as the Moon or near Earth asteroids. The effects of uncertainty in the model parameters are evaluated through sensitivity analysis of key parameters including the liquid propellant combination, inert mass fraction of the vehicle, change in velocity margin, and change in payload masses. The outcomes of this research include a description of the transportation elements, the architecture that they enable, and an option for a campaign that meets the objectives of the Evolvable Mars Campaign. This provides a more complete understanding of the propellant requirements, as a function of time, that must be delivered to cis-lunar space. Over the selected sensitivity ranges for the current payload and schedule requirements of the 2016 point of departure of the Evolvable Mars Campaign destination systems, the resulting propellant delivery quantities are between 34 and 61 tonnes per year of hydrogen and oxygen propellant, or between 53 and 76 tonnes per year of methane and oxygen propellant, or between 74 and 92 tonnes per year of hypergolic propellant. These estimates can guide future propellant manufacture and/or delivery architectural analysis.

McVay, Eric S.↗
NASA NTRS2017

NASA's Space Launch System: Enabling Exploration and Discovery

As NASA's new Space Launch System (SLS) launch vehicle continues to mature toward its first flight and beyond, so too do the agency's plans for utilization of the rocket. Substantial progress has been made toward the production of the vehicle for the first flight of SLS - an initial "Block 1" configuration capable of delivering more than 70 metric tons (t) to Low Earth Orbit (LEO). That vehicle will be used for an uncrewed integrated test flight, propelling NASA's Orion spacecraft into lunar orbit before it returns safely to Earth. Flight hardware for that launch is being manufactured at facilities around the United States, and, in the case of Orion's service module, beyond. At the same time, production has already begun on the vehicle for the second SLS flight, a more powerful Block 1B configuration capable of delivering more than 105 t to LEO. This configuration will be used for crewed launches of Orion, sending astronauts farther into space than anyone has previously ventured. The 1B configuration will introduce an Exploration Upper Stage, capable of both ascent and in-space propulsion, as well as a Universal Stage Adapter - a payload bay allowing the flight of exploration hardware with Orion - and unprecedentedly large payload fairings that will enable currently impossible spacecraft and mission profiles on uncrewed launches. The Block 1B vehicle will also expand on the initial configuration's ability to deploy CubeSat secondary payloads, creating new opportunities for low-cost access to deep space. Development work is also underway on future upgrades to SLS, which will culminate in about a decade in the Block 2 configuration, capable of delivering 130 t to LEO via the addition of advanced boosters. As the first SLS draws closer to launch, NASA continues to refine plans for the human deep-space exploration it will enable. Planning currently focuses on use of the vehicle to assemble a Deep Space Gateway, which would comprise a habitat in the lunar vicinity allowing astronauts to gain experience living and working in deep space, a testbed for new systems and capabilities needed for exploration beyond, and a departure point for NASA and partners to send missions to other destinations. Assembly of the Gateway would be followed by a Deep Space Transport, which would be a vehicle capable of carrying astronauts farther into our solar system and eventually to Mars. This paper will give an overview of SLS' current status and its capabilities, and discuss current utilization planning.

Schorr, Andrew↗
NASA NTRS2017

NASA's Space Launch System: Enabling Exploration and Discovery

As NASA's new Space Launch System (SLS) launch vehicle continues to mature toward its first flight and beyond, so too do the agency's plans for utilization of the rocket. Substantial progress has been made toward the production of the vehicle for the first flight of SLS - an initial "Block 1" configuration capable of delivering more than 70 metric tons (t) to Low Earth Orbit (LEO). That vehicle will be used for an uncrewed integrated test flight, propelling NASA's Orion spacecraft into lunar orbit before it returns safely to Earth. Flight hardware for that launch is being manufactured at facilities around the United States, and, in the case of Orion's service module, beyond. At the same time, production has already begun on the vehicle for the second SLS flight, a more powerful Block 1B configuration capable of delivering more than 105 metric tons to LEO. This configuration will be used for crewed launches of Orion, sending astronauts farther into space than anyone has previously ventured. The 1B configuration will introduce an Exploration Upper Stage, capable of both ascent and in-space propulsion, as well as a Universal Stage Adapter - a payload bay allowing the flight of exploration hardware with Orion - and unprecedentedly large payload fairings that will enable currently impossible spacecraft and mission profiles on uncrewed launches. The Block 1B vehicle will also expand on the initial configuration's ability to deploy CubeSat secondary payloads, creating new opportunities for low-cost access to deep space. Development work is also underway on future upgrades to SLS, which will culminate in about a decade in the Block 2 configuration, capable of delivering 130 metric tons to LEO via the addition of advanced boosters. As the first SLS draws closer to launch, NASA continues to refine plans for the human deep-space exploration it will enable. Planning currently focuses on use of the vehicle to assemble a Deep Space Gateway, which would comprise a habitat in the lunar vicinity allowing astronauts to gain experience living and working in deep space, a testbed for new systems and capabilities needed for exploration beyond, and a departure point for NASA and partners to send missions to other destinations. Assembly of the Gateway would be followed by a Deep Space Transport, which would be a vehicle capable of carrying astronauts farther into our solar system and eventually to Mars. This paper will give an overview of SLS' current status and its capabilities, and discuss current utilization planning.

Robinson, Kimberly F.↗
NASA NTRS2018

Marshall Space Flight Center Research and Technology Report 2017

This report features over 60 technology development and scientific research efforts that collectively aim to enable new capabilities in spaceflight, expand the reach of human exploration, and reveal new knowledge about the universe in which we live. These efforts include a wide array of strategic developments: launch propulsion technologies that facilitate more reliable, routine, and cost effective access to space; in-space propulsion developments that provide new solutions to space transportation requirements; autonomous systems designed to increase our utilization of robotics to accomplish critical missions; life support technologies that target our ability to implement closed-loop environmental resource utilization; science instruments that enable terrestrial, solar, planetary and deep space observations and discovery; and manufacturing technologies that will change the way we fabricate everything from rocket engines to in situ generated fuel and consumables.

Research and Technology Report↗
NASA NTRS2018

Daring You to Ask What If? Centennial Challenges

Centennial Challenges: Cube Quest - Propulsion, communication around Moon and into deep space; 3D-Printed Habitat - Additive construction for in-space habitats using regolith and recyclables; Vascular Tissue - 3D-printed human organ tissue to advance medicine in space and on Earth; CO2 Conversion - Bio-manufacturing using carbon dioxide and in-situ resources on Mars; Space Robotics II - Autonomous robotic navigation and decision systems for ISRU tasks.

Centennial challenges↗
NASA NTRS2018

NASA's Space Launch System: Unprecedented Payload Capabilities

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

Creech, Steve↗
NASA NTRS2018

Design Optimisation and Mass Saving of the Structure of the Orion-MPCV European Service Module

This paper presents an overview of the design optimisation measures that have been proposed and analysed in order to reduce the mass of the structure, including the MMOD (Micro-Meteoroid and Orbital Debris) protection system, of the ESM (European Service Module) for the “Orion” MPCV (Multi-Purpose Crew Vehicle). Under an agreement between NASA and ESA, the NASA Orion MPCV for human space exploration missions will be powered by a European Service Module, based on the design and experience of the ATV (Automated Transfer Vehicle). The development and qualification of the European Service Module is managed and implemented by ESA. The ESM prime contractor and system design responsible is Airbus Defence and Space. Thales Alenia Space Italia is responsible for the design and integration of the ESM Structure and MMOD protection system in addition to the Thermal Control System and the Consumable Storage System. The Orion Multi-Purpose Crew Vehicle is a pressurized, crewed spacecraft that transports up to four crew members from the Earth’s surface to a nearby destination or staging point. Orion then brings the crew members safely back to the Earth’s surface at the end of the mission. Orion provides all services necessary to support the crew members while on-board for short duration missions (up to 21 days) or until they are transferred to another orbiting habitat. The ESM supports the crew module from launch through separation prior to re-entry by providing: in-space propulsion capability for orbital transfer, attitude control, and high altitude ascent aborts; water and oxygen/nitrogen needed for a habitable environment; and electrical power generation. In addition, it maintains the temperature of the vehicle's systems and components and offers space for unpressurized cargo and scientific payloads. The ESM has been designed for the first 2 Lunar orbit missions, EM-1 (Exploration mission 1) is an un-crewed flight planned around mid-2020, and EM-2, the first crewed flight, is planned in 2022. At the time where the first ESM is about to be weighted, the predicted mass lies slightly above the initial requirement. For future builds, mass reduction of the Service Module has been considered necessary. This is being investigated, together with other design improvements, in order to consolidate the ESM design and increase possible future missions beyond the first two Orion MPCV missions. The mass saving study has introduced new optimised structural concepts, optimisation of the MMOD protection shields, and optimised redesign of parts for manufacturing through AM (Additive Manufacturing).

Micro-Meteroids and Orbital Debris Protection Syst↗