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.

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Misuse revealed of vomit comet at NASA

It appears that, stuck with the “vomit comet” airplane that they no longer had much use for, NASA managers tried to justify its existence and budget by assigning it tasks for which it and its crew were not designed or trained to do.

The unorthodox use of the C-9 aircraft was driven, according to the complaints, by a desire at the high levels of the agency to prove the Vomit Comet was of practical use. Apparently, it didn’t work—the C-9 aircraft program was defunded and shut down in 2014.

Since 1959, NASA has used a variety of aircraft to simulate the weightlessness of space in order to train astronauts and perform basic experiments in zero gravity. From 2005 to 2014, the C-9, built in 1970, became one of NASA’s primary Vomet Comets. According to documents uncovered by Motherboard using the Freedom of Information Act (embedded at the bottom of this article) show that the Vomit Comet was used on at least two occasions for purposes other than simulating space flight, while still labeling the missions “crew training.” In 2013, the agency officially looked into having the plane reclassified to run these types of missions.

In one of these cases, the plane was flown to Greenland without the proper equipment or training for the crew, and experienced what was described by crew as “a near fatal crash.” It didn’t crash, but the crew apparently feared for their lives.

The program was shut down in 2014 with the operations handed over to private companies. Now if NASA needs to train astronauts, they simply hire these companies, which make the bulk of their money flying private missions, something NASA wasn’t allowed to do.

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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.

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New Horizons’ future research goals

On Monday at a planetary science conference Alan Stern, the project scientist for New Horizons, outlined the science goals in studying the Kuiper Belt should the spacecraft’s mission be extened through 2021.

The main goal will be the January 1, 2019 fly-by of Kuiper Belt object 2014 MU69, estimated to be between 12 to 24 miles across. However, the proposal also includes the following:

“In addition to making a close flyby of MU69, we’re also going to be close enough in range to study quite a number of other small KBOs, and some large ones that are on the Pluto scale,” Stern said. New Horizons will be able to study them in ways that could never be accomplished from Earth. The closeness of the spacecraft will enable high resolution observations, and the ability to look for satellites that cannot be seen from Earth observatories or with the Hubble Telescope.

“Because we are looking back on the rest of the solar system, at the Kuiper Belt and the Centaur Population,” Stern said, “we’re going to be able to study another 18 or 20 small bodies to determine whether or not the recently discovered rings around the centaur Chariklo are a common occurrence, or something anomalous. And I don’t know of any other way over the next several years, except through New Horizons, that we can develop a data set like that.”

What I find amazing is that it appears from Stern’s remarks that NASA has not yet approved this proposal. Before the team discovered 2014 MU69, I would have been more skeptical about extending the mission, but since they will be able to do a close fly-by of a type of object never before seen, and considering the time and cost it takes to get to the Kuiper Belt, it seems foolish now to not approve this mission extension.

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Atlas 5 launches Cygnus

The competition heats up: A ULA Atlas 5 rocket tonight successfully placed an Orbital ATK Cygnus freighter into orbit to resupply ISS.

This was the second time an Atlas 5 put Cygnus into orbit. The next Cygnus flight will mark the return of Orbital’s Antares rocket.

This Cygnus capsule contains probably one of the more interesting engineering experiments flown by NASA in years. When it leaves ISS in about two months they will ignite a fire inside it to study the way fires spread and burn in weightlessness.

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SpaceX sets date for next Dragon launch

The competition heats up: SpaceX has scheduled April 8 for the next Falcon 9 launch, set to carry its first Dragon capsule since the launch failure last year.

Though this is the most important news contained by the article, its focus is instead on the various preparations that SpaceX is doing at its Texas test facility to prepare for this launch as well as the increased launch rate required for the company to catch up on its schedule.

Note that the Dragon launch will also be significant in that it will be carrying Bigelow’s inflatable test module for ISS, built for only $17 million in less than 2 years. NASA, ESA, or JAXA would have required at least half a billion and several years to have accomplished the same.

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Starting a fire in space, on purpose

Engineers plan to intentionally start fires in every Cygnus capsule heading for ISS this year, beginning with the next on Tuesday, but they will wait each time until the freighter has been docked, unloaded, and has left the station.

“The specific goals of the SAFFIRE experiments are to investigate the spread of a large-scale fire in microgravity, essentially trying to answer the questions of how large does a fire get and how rapidly does it spread, or how long does it take to get to the point of being really hazardous to the crew.”

NASA intends to run SAFFIRE experiments on three consecutive Cygnus spacecraft launching through the end of this year. The SAFFIRE 1 and 3 tests will use single samples 15.7 inches wide by 37 inches tall to watch the development and spread of a large-scale low-gravity fire. Scientists want to know if there is a limiting flame size and to quantify the size and growth rate of flames over large surfaces. “SAFFIRE is a box with a wind tunnel in it, a flow duct, that contains the sample that will be burned,” said Ruff. With two cameras poised to capture the fire, a hot wire along the upstream edge of the fiberglass-cotton fabric sample will trigger the burn that should last at least 15 or 20 minutes.

This is very clever, using the capsule as a fire test facility when it is on its way back to Earth to burn up in the atmosphere.

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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.

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NASA reschedules rather than cancels InSight

Forced to delay its launch because its primary instrument, built by the French, would not be ready for its 2016 launch, NASA has decided to go on with the InSight Mars mission, rescheduling it for a May 2018 launch, rather than cancelling it outright.

The seismometer, built by the French space agency CNES, will be repaired in time to make the 2018 launch window, said Jim Green, the head of NASA’s planetary sciences division in Washington DC. “That’s terrific news,” he told a planetary sciences advisory panel on 9 March. The Jet Propulsion Laboratory in Pasadena, California, will assume responsibility for building a new vacuum enclosure for the seismometer.

The last sentence above suggests that NASA has decided to take certain responsibilities from the French to make sure they get done right. It also means that the cost will be born by the NASA’s planetary program, cutting into other possible future missions.

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Apollo 11 First Stage liftoff in Ultra Slow Motion

An evening pause: This footage was taken on July 16, 1969 at 500 frames per second, and shows only what happened at the base of the launch tower as the engines of the Saturn 5 rocket ignited and lifted the rocket into the air. Though the video is more than 8 minutes long, the actual events recorded lasted only about 30 seconds, beginning 5 seconds before T minus 0.

What struck me most as I watched this was the incredible amount of complex engineering that went into every single small detail of the rocket and the launch tower and launchpad. We tend to take for granted the difficulty of rocket engineering. This video will make you appreciate it again.

It is also mesmerizing. A lot happens in a very short period of time.

Hat tip Kyle Kooy.

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NASA bans employees from writing the word “Jesus”

The new fascism: Lawyers at NASA have ruled that the agency has the right to ban the use of the word “Jesus” in any email written by employees.

In a letter sent Monday, the Liberty Institute stated that NASA lawyers pressured a group of employees at the Johnson Space Center to remove the word “Jesus” from a club announcement. This demand took place in May and June of 2015.

These employees had formed a private group within the agency called the JSC Praise and Worship Club, an entity separate from the agency. As part of the group, employees meet together during lunch to pray, and no one is prevented from taking part in the group’s activities. In an announcement email, one of the employees had used the word “Jesus.” A few days after the email went out, NASA lawyers clamped down and said the use of the word was absolutely unacceptable and would not accept the group’s offer to issue any kind of disclaimer to downplay its use.

NASA is now going to be sued by these individuals, as the agency is clearly acting to deny them their first amendment rights. And NASA deserves to be sued, and to lose badly in court. It is absurd that those NASA lawyers can construe the writing of the word “Jesus” by a single employee as an endorsement by the agency of that religion. These same lawyers would have also acted to ban the Apollo 8 astronauts from reading from the Old Testament while in orbit around the Moon in 1968. They are thus no different than the Soviet overlords with whom we were fighting the Cold War at the time.

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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.

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February 2, 2016 Batchelor podcast

Below the fold is Tuesday’s podcast of my appearance on the John Batchelor show. In addition to discussing Falcon Heavy, Ariane 6, and the question of rocket re-usability, I also lambasted the glacially slow pace of NASA’s Orion project, producing four capsules for a mere $17 billion in only 19 years! And speaking of glaciers, I also noted in the science segment the stonewalling at NOAA that prevents scientists from analyzing the rational behind their “adjustments” to their climate data, all of which cool the past and warm the present.
» Read more

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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.

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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.

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Private company proposes commercial airlock for ISS

The competion heats up: The private company NanoRacks has proposed building a large airlock for ISS which could be used to launch private cubesates while also allowing NASA to eliminate spacewalks by bringing faulty equipment inside for repairs.

For commercial opportunities, NanoRacks has a small satellite launcher, and it is also designing a “haybale” system to launch as many as 192 cubesats at a time. After the airlock is configured, it would be depressurized and sealed. Then a station robotic arm could grab it, move it away from the vehicle, and deploy its payloads.

NASA is also interested in the opportunity to potentially fix large, external components of the space station. Before the space shuttle’s retirement, NASA used the sizable delivery vehicle to stash dozens of replacement pumps, storage tanks, controller boxes, batteries, and other equipment on the station, known as ORUs. When one of these components broke, astronauts would conduct a spacewalk to install a replacement unit.

However sometimes the problem with a broken unit is relatively minor, such as a problematic circuit card. With a larger airlock, damaged components could be brought inside the station, assessed, and possibly fixed, saving NASA the expense of building and delivering a new unit to the station—or losing a valuable spare. Finally, the space agency could use the airlock to dispose of trash that accumulates on station and can be difficult to get rid of.

It is exactly this kind of technology, spurred by the lure of profits, that interplanetary spaceships need if they are going to be maintainable far from home.

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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.

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Spacewalk cut short due to spacesuit water leak

Today’s spacewalk at ISS to repair a failed voltage regulator of the station’s power system has been cut short because a water bubble had appeared inside one of the astronaut’s spacesuit.

The astronauts are presently in the airlock about to remove their spacesuits, so it appears they are not in danger. However, this problem is the return of the earlier water leaks inside NASA’s spacesuits, something that the agency had thought it had solved last year. If it has returned, this is of serious concern, since it suggests that they have not yet pinpointed the chronic cause of the problem.

It should be noted that the astronauts had successfully replaced the voltage regulator prior to the premature conclusion of their spacewalk. They had had other less critical tasks on their schedule which they had to forego because of the leak.

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