Tag Archives: SLS

The status of SLS for its first launch in 2018

Link here. The article gives an excellent and detailed overview of where construction of SLS presently sits, what the problems are that still remain, and what they have done to overcome them.

What struck me most however in reading the article was how long it takes them to do anything. For example, it appears they will assemble the rocket in the spring of 2018 for a December launch. In fact, the description of this assembly in this article partly explains to me why SLS will have the ungodly slow launch rate of at best once every two years.

In addition, the article describes how NASA has handled a number of engineering issues that have come up, and for each the approach seems to me to be more complicated than necessary. However, I am not an engineer and have never been part of this kind of work. Maybe everyone does it this way.

NASA finalizes more cubesat deals for first SLS launch

Lockheed Martin and NASA have signed a deal to put a science cubesat on the first SLS rocket, planned for an unmanned launch of Orion in 2018.

The adapter ring that connects Orion to the rocket will include 13 bays for CubeSats, shoe-box sized payloads that until now haven’t been delivered in significant numbers into deep space. Each of those payload operators is working to finalize contracts with NASA for the ride into space, and on Monday, Lockheed Martin announced a few details of its 6U CubeSat, called SkyFire. Lockheed’s payload will capture high-quality images of the Moon. And in exchange for the ride into deep space, NASA will receive data from the mission.

“The CubeSat will look for specific lunar characteristics like solar illumination areas,” James Russell, Lockheed Martin SkyFire principal investigator, said in a news release. “We’ll be able to see new things with sensors that are less costly to make and send to space.”

This is without doubt a great opportunity for Lockheed Martin and others to test the use of a cubesat in interplanetary space. Whether it makes sense to use SLS to launch them is another matter entirely.

NASA delays asteroid redirect mission one year

NASA has decided to delay by one year the planned launch dates for both its unmanned and manned missions to an asteroid.

And why might you ask?

Mr. Gerstenmaier further stated that “We had trouble getting the funding together for this thing. So this slip of the one year that you see wasn’t caused by technical. It was really caused by budget availability. We just didn’t have the budget available to go do this.”

Also, the article notes that the launch rocket for the unmanned mission, now set for 2021, will be one of three possible rockets.

No elaboration was given as to what those “three rockets” are, though SLS, one of SpaceX’s Falcon family of rockets, and Atlas V are understood to be the prime contenders at this time.

The unmanned mission might happen (though I wouldn’t bet on it). As for the manned mission, there is a reason NASA has had trouble getting funding. SLS/Orion cost too much. Congress simply doesn’t want to spend that much for the actual missions. They will dole out a lot of cash for development (and the pork that goes with it), but even they can’t afford the gigantic budgets NASA needs to actually fly real missions.

July 29, 2016 Zimmerman/Batchelor podcast

The podcast is now fixed and available! John Batchelor thanks Willi for spotting the problem.

Embedded below the fold. John Batchelor titled this appearance very accurately: “Condemning Orion.” He likes to say that I am sometimes cranky. I was especially cranky tonight in reviewing why I think the way NASA is selling Orion is an outright lie.
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GAO warns of more cost overruns for SLS/Orion

The Government Accountability Office today issued two reports, both of which said that the SLS and Orion programs are faced with more cost overruns and schedule delays.

The GAO found that cost overruns for Orion could be as high as $707 million and that work is “not being accomplished as scheduled.” It also found challenges with the capsule’s software and heat shield, and said that the space capsule’s cost and schedule “estimates are not reliable.”

Other than that, everything is peachy keen! These reports, (the Orion report is found here [pdf] and the SLS report here [pdf], especially the Orion one, also suggest that the first manned Orion mission, now scheduled for 2021, stands a good chance of being delayed again, possibly for two more years.

This just confirms what I have written in my soon-to-be published policy paper, Exploring Space in the 21st Century. In fact, I need to add these GAO reports to my sources!

The Lie that is Orion

Several weeks ago NASA put out one of its periodic press releases touting the wonders of the engineering the agency is doing to prepare for its future missions to Mars. In this case the press release described a new exercise device, dubbed ROCKY (for Resistive Overload Combined with Kinetic Yo-Yo), for use in the Orion capsule.

“ROCKY is an ultra-compact, lightweight exercise device that meets the exercise and medical requirements that we have for Orion missions,” said Gail Perusek, deputy project manager for NASA’s Human Research Program’s Exploration Exercise Equipment project. “The International Space Station’s exercise devices are effective but are too big for Orion, so we had to find a way to make exercising in Orion feasible.

As is their habit these days in their effort to drum up support for funding for SLS and Orion, the press release was filled with phrases and statements that implied or claimed that Orion was going to be the spacecraft that Americans will use to explore the solar system.

…engineers across NASA and industry are working to build the Orion spacecraft and Space Launch System rocket that will venture to deep space for the first time together…

…Over the next several years, NASA’s Human Research Program will be refining the device to optimize it not only for near-term Orion missions with crew, but for potential uses on future long-duration missions in Orion…

These are only two examples. I have clipped them because both were very carefully phrased to allow NASA deniablity should anyone question these claims. For example, in the first quote they qualify “deep space” as specifically the 2018 unmanned lunar test flight. And the second quote is qualified as referring to missions to lunar space. Nonetheless, the implied intent of this wording is to sell Orion as America’s interplanetary spaceship, destined to take us to the stars!

Don’t believe me? Then take a look at NASA’s own Orion webpages, starting with the very first words on their Orion Overivew page.
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SLS engine shuts down prematurely during test

A static firing test of one SLS’s rocket engines, repurposed from the shuttle, ended prematurely on Thursday.

It appears there was “a minor issue with the test stand” that caused the early shutdown. Some history about the engine itself:

The test involved development Engine 0528, back in the test stand at Stennis for its first test firing in seven years. E0528 was last fired from the nearby A-2 stand on July 1, 2009, in the second-to-last Space Shuttle Main Engine (SSME) ground test for the Shuttle program. Now out of storage and ready to fire again, the Aerojet Rocketdyne engine is being used in a second series of tests of the RS-25 configuration that will fly on SLS.

This is a test program, so having things go wrong is not necessarily a problem, as the failure teaches you things you need to know. However, they aren’t supposed to be testing the test stand, they are supposed to be testing the engine.

A description of SLS’s first launch

This article provides a detailed look at the planned 2018 first launch of SLS, describing step-by-step the launch process that will send an unmanned Orion capsule toward the Moon.

As my readers know, I am not a fan of SLS. I consider it an incredible waste of money that will never accomplish anything. Nonetheless, that first launch will be a cool thing to watch, as the rocket will generate comparable energy as the Saturn 5.

Airbus begins assembly Orion service module

My heart be still! Airbus has announced that it is beginning assembly of the first Orion capsule service module.

Considering the cost to build about three Orion flight capsules, about $25 billion, one would think that would be enough to also build the capsule’s service module, especially since this is not cutting edge technology, having already been done with Apollo.

Not however when you are dealing with pork-laden government operations, where the customer, the taxpayer, is a good mark that you can suck for as much money as possible without any bad consequences. Make it sound cool and they will buy it, hook, line, and sinker!

The Orion fantasy

There is a commercial space conference going on in Colorado this week, which explains the plethora of breaking stories from the new commercial space companies both yesterday and today.

Two stories today from Aviation Week, however, are more about the old big space industry and the old way of doing things, and both reveal the hollow nature of that entire effort.

Both stories are about work Lockheed Martin is doing in connection with its Orion capsule, and both try to convince us that this capsule is going to be the central vehicle for the first missions to Mars.

Function starts in the bones of the spacecraft,” [Mike Hawes, Lockheed Martin vice president and Orion program manager,] said in an April 12 interview at the 32nd annual Space Symposium here. “To be a deep space spacecraft, you have to build differently than you would if your requirements were to stay in low Earth orbit and be quiescent at the International Space Station for a few months. That’s driven Orion from the beginning. Any architecture you look at needs a crew capability, a long-term design requirement. So, you can debate a lot of different missions, but you need that fundamental capacity we have invested in Orion.”

I say balderdash. Orion is an over-priced and over-engineered ascent/descent capsule for getting humans in and out of Earth orbit. Spending billions so it can also go to Mars makes no sense, because its heat shield and other capsule technologies for getting through the Earth’s atmosphere are completely useless in interplanetary travel. Moreover, such a small capsule is completely insufficient for a long Mars mission, even if you test it for a “1,000 day” missions, as Hawes also says in the first article. To send a crew to Mars, you need a big vessel, similar to Skylab, Mir, ISS, or Bigelow’s B330 modules. A mere capsule like Orion just can’t do it.

Eventually, it is my hope that Congress will recognize this reality, and stop funding big space projects like SLS and Orion, and instead put its money behind the competitive private efforts to make money in space. Rather than trying to build its own capsules, space stations, rockets, and interplanetary vessels (something that NASA has repeatedly tried to do without any success), NASA should merely be a customer, buying the capsules, space stations, and interplanetary vessels that private companies have built, on their own, to make money, on their own.

Consider for example Bigelow’s B330. Each module is about as big as Skylab or Mir, and costs mere pennies to build and launch, compared to those government-designed stations. Moreover, Bigelow can build it fast, and repeatedly. Similarly, Orion has cost billions (about $16 billion when it makes its first manned mission in 2021 at the earliest) and will have taken 15 years to build. SpaceX built Dragon in seven years, Orbital ATK built Cygnus in five years, and Boeing is going to build Starliner in about four years, all for about $10 billion, total.

The contrast is striking, and though ordinary people with the ability to add 2 plus 2 can see it, it takes Congressman a little longer (as they need to use their fingers to count). Sooner or later they will get it, and Orion and SLS will disappear. Bet on it.

NASA picks Aerojet Rocketdyne engine for SLS upper stage

Government in slow motion: Only six years after program start, NASA has finally chosen Aerojet Rocketdyne’s legacy RL10 rocket engine for the upper stage of the SLS rocket.

The RL10 is an expander cycle liquid hydrogen/liquid oxygen rocket engine typically used on upper stage applications. It was first developed by Pratt & Whitney in the late 1950s and first flown in 1963. It has flown on hundreds of launches, logged approximately 15,000 hot fires, and accumulated more than 2.3 million seconds of hot fire operation time with a demonstrated reliability ratio greater than 0.999 throughout its history. The RL10 – which is used in various forms with Atlas’ Centaur Upper Stage (RL10A-4-2) and Delta IV’s Upper Stage (RL10B-2) – has a history back to the Saturn I’s S-IV Stage.

No other engine exists that can be built in time. Even so, the engine will not be ready for the first SLS launch tentatively scheduled in 2018, but will instead be used on the next two flights. The article also indicates that NASA is planning to delay SLS’s second flight two years to 2023, creating a five year gap which they will use to integrate the RL10 into SLS, while also rebuilding the mobile platform used to move SLS to the launchpad. (For some reason, the reconfiguration installed for the first SLS flight won’t work for later flights.)

The delay to 2023 has not been announced officially, but I have seen too much evidence recently, including statements in this GAO report, that tells me the delay is certain. Furthermore, it seems increasingly likely that the second flight will also be unmanned, and it won’t be until the third flight (as yet unfunded by Coingress) that humans will finally fly on SLS.

The cost? I am doing an analysis of this subject right now for a policy paper I am writing for a Washington think tank, and my preliminary estimate exceeds $41 billion for NASA to fly just one manned flight of SLS. That’s a bit more expensive than the $10 billion NASA is paying SpaceX, Orbital ATK, and Boeing to launch more than a dozen cargo freighters and as many as a dozen manned flights to ISS.

For those elected officials out there who have trouble with math, let’s compare again:

  • SLS: $41 billion for one flight, 15 years development to first flight.
  • Commercial space: $10 billion for two dozen flights, 5 years development to first flight.

Which costs less and gives more bang for the buck? Can you figure that out, Congressmen and Senators? If you need help I can provide you a few more fingers so you can count above ten.

SLS software over budget and behind schedule

Surprise! The launch control software NASA is writing from scratch for its SLS rocket is way behind schedule and way over budget.

Development of this new launch control software is now projected to exceed $207 million, 77 percent above 2012 projections. The software won’t be ready until fall 2017, instead of this summer as planned, and important capabilities like automatic failure detection, are being deferred, the audit noted. The system is vital, needed to control pumps, motors, valves and other ground equipment during countdowns and launches, and to monitor data before and during liftoff.

NASA decided to write its own computer code to “glue together” existing software products a decade ago — while space shuttles still were flying and commercial shippers had yet to service the space station. Both delivery companies, SpaceX and Orbital ATK, rely on commercial software, the audit noted. [emphasis mine]

In other words, even though NASA could have simply purchased already available software that other launch companies were using successfully, the agency decided to write its own. And that decision really didn’t come before the arrival of these commercial companies, because when it was made a decade ago that was exactly the time that SpaceX was beginning to build its rocket.

This is simply more proof that SLS is nothing more than a pork-laden waste of money designed not to explore space but to generate non-productive jobs in congressional districts.

Second SLS flight delayed until 2023?

Government in action! The second flight of NASA’s SLS rocket, originally scheduled for around 2021 as the first manned mission, faces a possible delay of two years to 2023 so that it can be outfitted to launch the lander/orbiter planetary probe to Europa rather than flown manned.

The upper stage will be a new design that has never flown before. Thus, it has to be flown at least once unmanned to test it. Moreover, Congress in its most recent budget mandated that SLS be used for the Europa mission, probably in a team effort with NASA management to find a purpose for this missionless rocket that Congress has micromanaged from the beginning.

NASA has not officially decided to replace SLS’s original lunar manned mission for this second flight with the Europa mission, but I fully expect them to do so. They can’t fly the rocket with humans on it without first testing that upper stage engine at least once. Furthermore, the entire goal of SLS is not to fly missions but to employ people in Congressional districts. Delaying the first flight two years to outfit it for an unmanned planetary probe serves that absurd mission wonderfully.

The situation thus is that SLS will have a launch rate of once every five years, with a giant standing army of NASA and contractor employees paid during those years to do practically nothing while waiting for the next launch. While the article notes the high cost of building anything for SLS, it doesn’t explain that the reason things cost so much is that the government is slow-walking the construction of everything.

Note also that this means that Lockheed Martin will have an additional five years or so to finish its third Orion capsule. By that point the company will likely have spent about $20 billion, to build three capsules. Only a fool and a Congressman would consider this a good buy for the money.

Experts: NASA’s SLS Mars proposals bunk

The death of SLS begins: At House hearings this week, congressmen listened to several space experts who lambasted NASA’s asteroid and Mars mission proposals.

Paul Spudis of the Lunar and Planetary Institute and an expert on lunar science, was especially harsh.

“America’s civil space program is in disarray, with many aspirations and hopes but few concrete, realizable plans for future missions or strategic direction,” he said, adding that NASA lacks what it needs to pull off the mission (and throwing some shade at the agency’s strong Twitter game). “We pretend that we are on a ‘#JourneytoMars’ but in fact, possess neither the technology nor the economic resources necessary to undertake a human Mars mission now or within the foreseeable future. What is needed is a logically arranged set of short-term, realizable space goals–a series of objectives and destinations that are not only interesting in and of themselves, but whose attainment build space faring capability in the long term.”

The testimony claimed that it could cost anywhere from $500 billion to $1 trillion for NASA to get humans to Mars, numbers that are reasonable based on using NASA’s very costly and overpriced SLS/Orion rocket and capsule. The congressmen were of course interested in this, not because they want to get to Mars, but because they see gobs of pork for their districts in these numbers.

However, I expect that when SpaceX begins successfully launching its Falcon Heavy rocket in the next two years while simultaneously putting humans in space with its Dragon capsule, and does both for a tenth the cost of SLS/Orion, those same congressmen will dump SLS/Orion very quickly. Though they want the pork, they also know they don’t have $500 billion to $1 trillion to spend on space. The private sector gives them an option that is both affordable and of strong self-interest. The more realistically priced and designed hardware of private companies will give them a more credible opportunity to fund pork in their districts.

First SLS launch will carry 13 cubesats

NASA today announced that the first test flight of its giant SLS rocket, more powerful than the Saturn 5 and intended to make human missions beyond Earth orbit possible, will carry 13 cubesats in addition to its Orion capsule.

Because the mission plans on sending the unmanned Orion on an Earth orbit beyond the Moon, these cubesats will have an opportunity to go where no cubesat has gone before.

NASA ships a capsule

In what appears to me to be a overwrought attempt to make the minor shipment of one Orion capsule appear to be a major achievement, NASA on Monday transported the next Orion capsule from Louisiana to Florida.

They used the NASA’s Super Guppy cargo plane to do it, even though I suspect that the capsule really isn’t that large and could have likely been shipped by road in a truck for a lot less. The agency also apparently made a big deal about this shipment with the press, which like sheep went along with it.

The pictures here illustrate what I mean. I grant that the Super Guppy is a cool plane, and it is certainly fun to see how it is loaded and flies, but from a cost perspective this seems to be a very expensive way to transport the capsule.

As a result, the impression this all leaves me with is that NASA is really not doing very much with Orion, working at a snail’s pace to stretch out the payments, and thus has to sell every little thing to convince the public that this project is accomplishing a lot.

Orion: construction in slow motion

Today NASA announced completion of the welding of the next Orion capsule, a job that this story said took about three months to do 7 welds. The story also noted this:

After putting on the finished touches, NASA plans to ship the vehicle to the Kennedy Space Center (KSC) aboard NASA’s Super Guppy airplane on or about Feb. 1. At KSC, engineers working inside the Neil Armstrong Operation and Checkout Building (O & C) will spend the next two years outfitting Orion for launch in late 2018 by installing all the systems and subsystems for its inaugural flight to the Moon and back.

Overall this is the third Orion capsule that NASA has built, following the Ground Test Article (GTA), which did not fly, and the EFT-1 capsule which successfully launched just over one year ago on Dec. 5, 2014. [emphasis mine]

Three months to do 7 welds. Two years to outfit a capsule. Wow! At that pace they might launch before the end of the century.

Seriously, this is an absurdly slow work pace, illustrating the wasteful nature of the SLS/Orion program. Orion’s budget these days is about $1 billion per year, with a total cost expected to reach $17 billion by the time the fourth capsule is built and launched in 2023, for a project first proposed in 2004.

In other words, it will take NASA and Lockheed Martin almost 20 years to build four capsules for the cost of $17 billion. That is absurd. Compare it to commercial space: The entire budget for all the commercial crew contracts, including both cargo contracts and the manned contract, is about half that, and will produce four different vehicles, all of which will be built and flying by 2019 at the latest. And in the case of Dragon and Cygnus, more than a dozen capsules have already flown.

Is there no one in Washington with the brain power to read these numbers and come to a rational decision about SLS/Orion? It costs too much and isn’t getting us into space. Moreover, at its pace and cost it isn’t doing anything to help the American aerospace industry. Better for Congress to put money into other things, or save it entirely and reduce the deficit and thus not waste it on this pork barrel garbage.

Unfortunately, our elected officials today not only don’t have brains, too many of them are downright corrupt. They prefer to bankrupt the nation for their own petty gain rather than do things that might help the nation grow.

SLS still has no mission

At a meeting at the Kennedy Space Center on Monday, outlining the status of the Orion/SLS program, managers admitted that the program still lacks funding for any missions past its initial 2018 unmanned test flight.

Internally, a huge amount of work is continuing to take place on providing SLS with Design Reference Missions (DRMs). However, those are only for planning purposes and the outlook continues to change, resulting in uncertainty. Numerous factors are to blame, with funding once again mentioned as an issue during the KSC meeting – citing SLS is “lacking booked missions at this time due to tight funding.”

In other words, Congress has not provided NASA any funding for any real SLS missions. I also don’t expect Congress to ever do so, since the cost per launch ranges from $3 to $14 billion, depending on how you calculate the numbers. This is in comparison to the estimated per launch cost of about $100 to $150 million for a Falcon Heavy launch, capable of putting in orbit about two-thirds that of SLS. Even a stupid Congressmen can read these numbers and figure out that they will get a lot more bang per buck dumping SLS for Falcon Heavy.

NASA contracts Aeroject Rocketdyne to build shuttle engines for SLS

The competition heats up? NASA has awarded Aerojet Rocketdyne a $1.4 billion contract to restart production on the space shuttle engines, with the intent to use those engines for its hoped-for missions beyond Earth orbit using the Space Launch System (SLS).

Normally I am thrilled when an American company gets a contract to build rocket engines, but here I have my doubts. This contract will only produce deep space engines if Congress gives NASA the money to fly SLS on deep space missions. Right now, Congress has only given NASA just enough money to fly one, maybe two SLS missions, with the second not coming until 2024 at the earliest. My impression of this contract award thus is that it is not to produce engines, but to keep Aerojet Rocketdyne from going bust, since no one else has been interested recently in buying their engines. In other words, it is pork, government money handed out in order to keep the people who work for Aerojet employed.

This is not the way to become a space-faring society. Better Aerojet Rocketdyne goes bust and the good engineers that work for it find jobs with companies making products that people want. Then, the government money can be spent wisely on things that we will eventually want and use, instead of make-work projects that accomplish nothing.

NASA delays first Orion manned flight two more years

Surprise, surprise! NASA today announced that the first manned flight of the Orion capsule will likely be delayed two more years to 2023.

Orion has been under development since 2006, and is expected to have cost more than $17 billion when that first mission flies in 2023. SLS, once called Constellation but with a different configuration, has been under development since 2011, and has cost about that much through today. All told, I would estimate that by the time that flight occurs in 2023 (assuming it doesn’t get delayed again) NASA will have spent more than $40 billion.

This is a joke, but a very painful one. It is going to take NASA almost two decades to get one capsule off the ground. Compare that with the 1960s space race, where we went from nothing to landing on the Moon in a little more than eleven years.

If NASA had been spending this money on planetary missions, they might actually have been doing something worthwhile with it. Meanwhile, the private companies, SpaceX, Blue Origin, Boeing, Orbital ATK, are building capsules and rockets that are as capable, if not more so, and are getting them built now for less than a quarter that price, in the range of about $6 to $8 billion.

If our elected officials in Congress had any brains, they would shut Orion/SLS down now, and save the taxpayers an awful lot of money.

Cubesats to the Moon!

NASA has chosen three cubesat missions to fly lunar planetary orbiters to the Moon, to be launched on the first SLS flight in 2018.

LunaH-Map, along with a number of other deep-space CubeSats, is a candidate to fly to lunar orbit on Exploration Mission-1, the first flight of NASA’s Space Launch System (SLS), which will be the most powerful rocket ever built and will enable astronauts in the Orion spacecraft to travel deeper into the solar system. NASA will provide several CubeSat missions spots on the maiden SLS mission. LunaH-Map is a 6U (“6 unit”) CubeSat. One “unit” is a cube measuring 4.7 inches on a side; LunaH-Map strings six of these CubeSat building blocks together and weighs as much as a small child (about 30 pounds). …

“NASA has funded three different CubeSats to learn more: Lunar IceCube, Lunar FLASHLIGHT and LunaH-Map. They all look for water in different ways and provide different types of information,” [said principal investigator Craig Hardgrove].

The article is focused on LunaH-Map, not on the other two cubesats, but the fact that NASA plans to use “the most powerful rocket ever built” to launch the first three planetary cubesats, so small they could almost be launched by a model rocket, illustrates some of the problems of the SLS program. Even though that first SLS flight is likely to happen, I suspect that, should it falter for any reason (something that would not surprise me), these cubesats could easily be launched on another rocket, and will be.

Putting SLS aside, however, the building of these first planetary cubesats is a very significant development. It once again signals the way unmanned satellite engineering is evolving, finding ways to build spacecraft smaller and less costly.

Orion might not be ready for 2018 test flight

Government in action! Last week NASA admitted that the Orion capsule and its service module might not be ready for its 2018 test flight.

Bill Gerstenmaier, head of NASA’s human spaceflight directorate, told members of the [NASA Advisory Council’s human exploration] subcommittee the Orion capsule’s European-made service module, which is being developed by Airbus Defense and Space, will probably be the last piece of the critical test flight to be ready for launch.

NASA and ESA officials, together with contractors from Orion-builder Lockheed Martin and Airbus, have discussed shipping the Orion service module from Europe to NASA’s Kennedy Space Center in Florida before it is finished. European engineers could travel to the Florida spaceport to complete construction of the service module before its integration with the Orion crew capsule, which is to be assembled by Lockheed Martin at KSC’s Armstrong Operations and Checkout Building.

Engineers plan to introduce changes to the Orion crew module after a successful orbital test flight in December 2014. The upgrades include a switch from a monolithic heat shield made of ablative Avcoat material to blocks of Avcoat, a change intended to improve the manufacturability of the thermal protection system. [emphasis mine]

I have highlighted the last paragraph above because it is written to give the false impression that the decision to change the heat shield resulted from the December 2014 test flight. The truth is that NASA had already decided to change heat shields before the test flight. Why NASA engineers are still “planning” to introduce these changes illustrates why government operations are absurdly wasteful.

Orion was first proposed by President George Bush in 2004. The first Orion contract was awarded in 2006. It is now a decade later, and NASA is suddenly warning us that they might not get a single capsule and service module built by 2018, 12 years after construction began. During that time they have spent approximately a billion dollars per year on Orion. For what?

Kennedy proposed going to the Moon in 1961. Eight years later Americans were walking there. Pearl Harbor was attacked on December 7, 1941. The U.S. completed the total defeat of Germany, Italy, and Japan in slightly more than three years, by the spring of 1945.

Today’s NASA however can’t get a single capsule and service module built in 12 years. The contrast is striking. Anyone with the slightest bit of common sense would say that with a track record like this, this program should be shut down now.

NASA considers offering SLS for commercial payloads

Squelching the competition: NASA is pushing to redesign its expensive and giant Space Launch System (SLS) rocket so that it can be used to launch commercial, military, and scientific payloads as well as proposed manned exploration missions.

At the moment, SLS has no planned payloads or funded flights past its second test flight in 2021. The system is very expensive, however, and the only way other customers could afford it would be if NASA charges them far less than the actual cost to fly. In such circumstances, NASA would essentially be subsidizing SLS so that it could compete, even undercut, private commercial rockets that actually cost far less.

If NASA does this, they could very well squelch the emerging private commercial launch industry.

Russia considers building heavy-lift rocket like SLS

The competition heats up: Sources in Roscosmos, Russia’s government agency in charge of their entire aerospace industry, today revealed that the agency is considering building a heavy-lift rocket, as powerful as NASA’s SLS rocket but more similar to Energia, the heavy-lift rocket built by the Soviet Union in the 1980s.

The cost would be $12.2 billion, or 1 trillion rubles, and would take 7-8 years to complete. If approved, the work would also not begin until after 2025 so that the development of Angara’s full family of rockets is completed first.

Meanwhile, a GAO audit today noted that NASA has little margin for completing SLS on time and on budget.

Big, inefficient, and costly rockets: This is what governments do. Their goal? To provide jobs and pork. Even if the rocket never flies it matters not, as long as that pork keeps flowing.

NASA to waste $150 million on SLS engine that will be used once.

Government marches on! NASA’s safety panel has noticed that NASA’s SLS program either plans to spend $150 million man-rating a rocket engine it will only use once, or will fly a manned mission without man-rating that engine.

The Block 1 SLS is the “basic model”, sporting a Delta Cryogenic Second Stage (DCSS), renamed the Interim Cryogenic Propulsion System (ICPS) for SLS. The current plan calls for this [interim] stage to be used on [the unmanned] Exploration Mission -1 (EM-1) and [manned] Exploration Mission -2 (EM-2), prior to moving to the [Exploration Upper Stage] – also to be built by Boeing – that will become the workhorse for SLS.

However, using the [interim upper stage] on a crewed mission will require it to be human rated. It is likely NASA will also need to fly the [Exploration Upper Stage] on an unmanned mission to validate the new stage ahead of human missions. This has been presenting NASA with a headache for some time, although it took the recent ASAP meeting to finally confirm those concerns to the public.

Up until now, no one at NASA would admit that their SLS plans called for flying humans with an upper stage that has not been man-rated. They don’t have the funds to man-rate it, and even if they get those funds, man-rating it will likely cause SLS’s schedule to slip even more, something NASA fears because they expect the commercial manned ships to be flying sooner and with increasing capability. The contrast — a delayed and unflown and very expensive SLS vs a flying and inexpensive commercial effort — will not do SLS good politically.

However, if they are going to insist (properly I think) that SpaceX and Boeing man-rate their capsules and rockets, then NASA is going to have to man-rate its SLS systems as well. The result: more problems for SLS, contributing to what I believe will be its inevitable cancellation.

Incorrectly built SLS welding machine to be rebuilt

You can’t make this stuff up. A giant welding machine, built for NASA’s multi-billion dollar Space Launch System (SLS), needs to be rebuilt because the contractor failed to reinforce the floor, as required, prior to construction.

Sweden’s ESAB Welding & Cutting, which has its North American headquarters in Florence, South Carolina, built the the roughly 50-meter tall Vertical Assembly Center as a subcontractor to SLS contractor Boeing at NASA’s Michoud Assembly Facility in New Orleans.

ESAB was supposed to reinforce Michoud’s floor before installing the welding tool, but did not, NASA SLS Program Manager Todd May told SpaceNews after an April 15 panel session during the 31st Space Symposium here. As a result, the enormous machine leaned ever so slightly, cocking the rails that guide massive rings used to lift parts of the 8.4-meter-diameter SLS stages The rings wound up 0.06 degrees out of alignment, which may not sound like much, “but when you’re talking about something that’s 217 feet [66.14 meters] tall, that adds up,” May said.

Asked why ESAB did not reinforce the foundation as it was supposed to, May said only it was a result of “a miscommunication between two [Boeing] subcontractors and ESAB.”

How everyone at NASA, Boeing, and ESAB could have forgotten to do the reinforcing, even though it was specified in the contract, baffles me. It also suggests that the quality control in the SLS rocket program has some serious problems.

Update: The original story at Space News that I originally linked to disappeared sometime in the next week, and was replaced with a slightly more detailed and more positive story, now linked above.

NASA to use giant SLS rocket to launch cubesats

The giant SLS rocket that NASA is building for billions will be used to launch eleven tiny 30 pound cubesats into deep space.

With room for 11 small shoebox-sized CubeSats on the first test flight of NASA’s behemoth Space Launch System, agency officials have turned to scientists, industry and students to fill the slots in time for launch in 2018. NASA has selected three CubeSats developed by internal government teams for flight on the SLS demonstration launch, and officials announced last week two more top candidates that could be manifested on the mission.

These will be the first cubesats ever sent beyond Earth orbit. Using SLS to get them into space, however, is very incongruous, since the very concept of cubesats is small and cheap, while SLS is everything but.

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