A engineering problem during construction of one of the shuttle-derived solid rocket boosters for SLS is causing delays.
A engineering problem during construction of one of the shuttle-derived solid rocket boosters for SLS is causing delays.
[The] original test target of mid-2013 slipped when an issue with the aft segment [of the booster] was found. Inspection of the segment showed it was contained an area where propellant had debonded from the inside of the segment wall. Following analysis – which notably found no voids in the propellant itself – NASA decided to ask ATK to scrap the segment and cast a replacement.
Preparations … continued, with the shipping and integration of forward and center segments at the test site, while ATK went to work to replace the aft segment, following approval – post investigation – from NASA’s Marshall Space Flight Center. After ATK successfully cast the replacement segment in July, technicians carried out routine ultrasound and x-ray tests. Unfortunately, the tests showed this segment had also had similar voids. [emphasis mine.]
The Space Launch System (SLS), was mandated by Congress to use as much shuttle-derived components as possible in order to supposedly save money as well as employ as many of the companies that built those components as possible. In reality, however, every one of those components has required significant redesign to make them work in SLS. In the case of the solid rocket boosters, the four segment shuttle boosters were not powerful enough. They had to be expanded to five segments.
Moreover, it appears from this article it was other technically unnecessary changes to the boosters that are now causing this problem.
The likely cause of the voids points to a change in processing when using a relatively new material in the insulation lining for the segments, a material that has replaced the previous use of crysotile – the most common mineral form of asbestos. The replacement of asbestos in the insulation package has been noted as one of ATK’s long-term goals. Crysotile-free rubber insulation had already been qualified for Shuttle, but never used in flight. It was then baselined for Ares I and subsequently for the SLS boosters. The previous insulation material used on the four segment shuttle boosters became obsolete as the shuttle fleet retired.
I suspect the replacement of crysotile was done to merely eliminate the use of asbestos in SLS, something that didn’t really improve the booster’s capability. Such unnecessary changes, which I suspect are taking place throughout SLS, might explain why SLS is costing so much and taking so long to build.
Readers!
Please consider supporting my work here at Behind the Black. Your support allows me the freedom and ability to analyze objectively the ongoing renaissance in space, as well as the cultural changes -- for good or ill -- that are happening across America. Fourteen years ago I wrote that SLS and Orion were a bad ideas, a waste of money, would be years behind schedule, and better replaced by commercial private enterprise. Only now does it appear that Washington might finally recognize this reality.
In 2020 when the world panicked over COVID I wrote that the panic was unnecessary, that the virus was apparently simply a variation of the flu, that masks were not simply pointless but if worn incorrectly were a health threat, that the lockdowns were a disaster and did nothing to stop the spread of COVID. Only in the past year have some of our so-called experts in the health field have begun to recognize these facts.
Your help allows me to do this kind of intelligent analysis. I take no advertising or sponsors, so my reporting isn't influenced by donations by established space or drug companies. Instead, I rely entirely on donations and subscriptions from my readers, which gives me the freedom to write what I think, unencumbered by outside influences.
You can support me either by giving a one-time contribution or a regular subscription. There are four ways of doing so:
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A engineering problem during construction of one of the shuttle-derived solid rocket boosters for SLS is causing delays.
[The] original test target of mid-2013 slipped when an issue with the aft segment [of the booster] was found. Inspection of the segment showed it was contained an area where propellant had debonded from the inside of the segment wall. Following analysis – which notably found no voids in the propellant itself – NASA decided to ask ATK to scrap the segment and cast a replacement.
Preparations … continued, with the shipping and integration of forward and center segments at the test site, while ATK went to work to replace the aft segment, following approval – post investigation – from NASA’s Marshall Space Flight Center. After ATK successfully cast the replacement segment in July, technicians carried out routine ultrasound and x-ray tests. Unfortunately, the tests showed this segment had also had similar voids. [emphasis mine.]
The Space Launch System (SLS), was mandated by Congress to use as much shuttle-derived components as possible in order to supposedly save money as well as employ as many of the companies that built those components as possible. In reality, however, every one of those components has required significant redesign to make them work in SLS. In the case of the solid rocket boosters, the four segment shuttle boosters were not powerful enough. They had to be expanded to five segments.
Moreover, it appears from this article it was other technically unnecessary changes to the boosters that are now causing this problem.
The likely cause of the voids points to a change in processing when using a relatively new material in the insulation lining for the segments, a material that has replaced the previous use of crysotile – the most common mineral form of asbestos. The replacement of asbestos in the insulation package has been noted as one of ATK’s long-term goals. Crysotile-free rubber insulation had already been qualified for Shuttle, but never used in flight. It was then baselined for Ares I and subsequently for the SLS boosters. The previous insulation material used on the four segment shuttle boosters became obsolete as the shuttle fleet retired.
I suspect the replacement of crysotile was done to merely eliminate the use of asbestos in SLS, something that didn’t really improve the booster’s capability. Such unnecessary changes, which I suspect are taking place throughout SLS, might explain why SLS is costing so much and taking so long to build.
Readers!
Please consider supporting my work here at Behind the Black. Your support allows me the freedom and ability to analyze objectively the ongoing renaissance in space, as well as the cultural changes -- for good or ill -- that are happening across America. Fourteen years ago I wrote that SLS and Orion were a bad ideas, a waste of money, would be years behind schedule, and better replaced by commercial private enterprise. Only now does it appear that Washington might finally recognize this reality.
In 2020 when the world panicked over COVID I wrote that the panic was unnecessary, that the virus was apparently simply a variation of the flu, that masks were not simply pointless but if worn incorrectly were a health threat, that the lockdowns were a disaster and did nothing to stop the spread of COVID. Only in the past year have some of our so-called experts in the health field have begun to recognize these facts.
Your help allows me to do this kind of intelligent analysis. I take no advertising or sponsors, so my reporting isn't influenced by donations by established space or drug companies. Instead, I rely entirely on donations and subscriptions from my readers, which gives me the freedom to write what I think, unencumbered by outside influences.
You can support me either by giving a one-time contribution or a regular subscription. There are four ways of doing so:
1. Zelle: This is the only internet method that charges no fees. All you have to do is use the Zelle link at your internet bank and give my name and email address (zimmerman at nasw dot org). What you donate is what I get.
2. Patreon: Go to my website there and pick one of five monthly subscription amounts, or by making a one-time donation.
3. A Paypal Donation or subscription:
4. Donate by check, payable to Robert Zimmerman and mailed to
Behind The Black
c/o Robert Zimmerman
P.O.Box 1262
Cortaro, AZ 85652
You can also support me by buying one of my books, as noted in the boxes interspersed throughout the webpage or shown in the menu above.
I can see trying to stop the use of the Asbestos but why was it not removed during the shuttles flight time?
The reasons for that could answer why its causing trouble now.
But why do engineers always want to “upgrade” proven systems when the old system worked just fine.
If they only plan on using shuttle components for the first flight right, then why make changes?
Variation on an old adage: “If it ain’t broke, fix it.”
this thing is a Political Tool and nothing more.