Tag: SLS

NASA IG: NASA’s effort to build new SLS mobile launcher is an epic disaster

12:20 pm

SLS's two mobile launchers, costing $1 billion
NASA’s bloated SLS mobile launchers

According to a new report [pdf] from NASA’s inspector general, both NASA and its contractor Bechtel have allowed the cost and schedule for the new larger SLS mobile launcher (ML-2) (on the right in the graphic) to go completely out of control, with the first launch on that platform to be delayed again until 2029.

NASA projects the ML-2 will cost over three times more than planned. In 2019, NASA estimated the entire ML-2 project from design through construction would cost under $500 million with construction completed and the ML-2 delivered to NASA by March 2023. In December 2023, NASA estimated the ML-2 project would cost $1.5 billion, including $1.3 billion for the Bechtel contract and $168 million for other project costs, with delivery of the launcher to NASA in November 2026. In June 2024, NASA established the Agency Baseline Commitment (ABC)—the cost and schedule baseline committed to Congress against which a project is measured—for a ML-2 project cost of $1.8 billion and a delivery date of September 2027. Even with the establishment of the ABC, NASA intends to keep Bechtel accountable to the cost and schedule agreed to in December 2023.

Despite the Agency’s increased cost projections, our analysis indicates costs could be even higher due in part to the significant amount of construction work that remains. Specifically, our projections indicate the total cost could reach $2.7 billion by the time Bechtel delivers the ML-2 to NASA. With the time NASA requires after delivery to prepare the launcher, we project the ML-2 will not be ready to support a launch until spring 2029, surpassing the planned September2028 Artemis IV launch date.

This quote actually makes things sounder better than they are. Bechtel’s original contract was for $383 million, which means the IG’s present final estimate of $2.7 billion is more than seven times higher. The contract was awarded in 2019 and was supposed to be completed by 2023, in four years. Instead, at best it will take Bechtel a decade to complete the job.

The IG notes that this contact was cost-plus, and considers this the main cause of these cost overruns. It also notes that NASA has had the option to convert the contract to fixed-price, but has chosen not to do so.

Possibly the most damning aspect of the IG report is its conclusion, which essentially admits that nothing can be done to fix this problem.
» Read more

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First SLS/Orion manned mission faces new delays because of Orion heat shield issues

9:39 am

Orion's damage heat shield
Damage to Orion heat shield caused during re-entry in 2022,
including “cavities resulting from the loss of large chunks”

Because the damage to the heat shield on the Orion capsule that flew around the Moon in late 2022 remains somewhat unexplained, NASA is considering delaying the next SLS/Orion mission, presently planned for September 2025 and intended to be the first Artemis flight to carry humans and take them around the Moon.

The heat shield, already installed at the base of the Orion spacecraft, will take the brunt of the heating when the capsule blazes through Earth’s atmosphere at the end of the 10-day mission. On the Artemis I test flight in late 2022, NASA sent an Orion spacecraft to the Moon and back without a crew aboard. The only significant blemish on the test flight was a finding that charred chunks of the heat shield unexpectedly stripped away from the capsule during reentry as temperatures increased to nearly 5,000° Fahrenheit (2,760° Celsius).

The spacecraft safely splashed down, and if any astronauts had been aboard, they would have been fine. However, the inspections of the recovered spacecraft showed divots of heat shield material were missing.

Two years later, despite extensive investigation and analysis, it appears NASA has not yet identified the root cause of the damage. The ablative material used on Orion was similar (though not identical) to the material used successfully on numerous other heat shields since the 1960s, yet it did not perform as expected.

NASA is presently facing three options. Do nothing and fly the next mission as planned, with four astronauts. It could rethink the trajectory used during re-entry, though this would likely not change things significantly unless the astronauts don’t go around the Moon as planned. Or it could change the heat shield itself.

The first two options are very risky, considering the unknowns. The latter involves a major delay of at least two years.

A decision must be made soon however. To meet the agency’s schedule it must begin stacking SLS’s two solid-fueled strap-on boosters next month. Those boosters have a limited life expectancy originally estimated to be one year. In the first unmanned Artemis test flight in 2022, NASA because of other delays stretched that life span to two years, and had no problems with the launch. If it stacks the boosters now and then has to delay for two more years to redesign Orion’s heat shield, those boosters will have been stacked for three years when launched.

Considering how seriously NASA is taking the issues with Starliner, which are likely not as serious as a heat shield that doesn’t work reliably, it would seem insane for NASA to launch Orion manned without fixing its own problem. And yet, for more than two decades NASA has consistently not demanded the same safety standards for SLS that it has demanded for the private commercial rocket startups. We shall see if this pattern now persists.

I continue to believe that the first Artemis lunar landing will not take place before 2030 (at least six years behind schedule). This heat shield dilemma only strengthens that prediction.

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NASA inspector general blasts Boeing’s management relating to its work on SLS’s new more powerful upper stage

9:52 am

Boeing's schedule slips in building SLS's upper stage
Boeing’s schedule slips in building SLS’s upper stage

In a report issued today [pdf], NASA’s inspector general harshly criticized the Boeing managment and operations at its Michoud facility, where the company is developing SLS’s new more powerful upper stage. From the report’s executive summary:

Quality control issues at Michoud are largely due to the lack of a sufficient number of rained and experienced aerospace workers at Boeing. To mitigate these challenges, Boeing provides training and work orders to its employees. Considering the significant quality control deficiencies at Michoud, we found these efforts to be inadequate. For example, during our visit to Michoud in April 2023, we observed a liquid oxygen fuel tank dome—a critical component of the SLS Core Stage 3—segregated and pending disposition on whether and how it can safely be used going forward due to welds that did not meet NASA specifications. According to NASA officials, the welding issues arose due to Boeing’s inexperienced technicians and inadequate work order planning and supervision. The lack of a trained and qualified workforce increases the risk that Boeing will continue to manufacture parts and components that do not adhere to NASA requirements and industry standards.

The report also notes that delivery of that upper stage has been delayed from 2021 to 2027 (as shown by the graph to the right, taken from the IG report), and its cost has risen from $962 million to almost $2.8 billion. It also notes quite bluntly that:

Boeing’s quality management system at Michoud does not effectively adhere to industry standards or NASA requirements, resulting in production delays to the SLS core and upper stages and increased risk to the integrated spacecraft. … Boeing’s process for addressing contractual noncompliance has been ineffective, and the company has generally been nonresponsive in taking corrective actions when the same quality control issues reoccur.

Sound familiar? It should. These issues appear to be the same kind of quality control problems that have plagued Starliner, and are also the same kind of problems that had NASA reject Boeing’s bid to provide cargo to its Lunar Gateway station, and state while doing so that it will no longer consider future Boeing bids until the company straightens itself out.

It appears from today’s inspector general report that Boeing has fixed nothing. The report recommends some additional supervision of Boeing from NASA, and more importantly suggests the agency “institute financial penalties for Boeing’s noncompliance with quality control standards.”

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Boeing to reduce staffing for SLS due to overall delays in Artemis

9:53 am

Boeing announced yesterday that it is going to reduce the staffing for its SLS rocket, caused by delays in other parts of the program that force it to stretch out operations.

When Boeing cites “external factors,” it is referring to the slipping timelines for NASA’s Artemis Program. In January officials with the space agency announced approximately one-year delays for both the Artemis II mission, a crewed lunar flyby, to September 2025; and Artemis III, a lunar landing, to September 2026. Neither of these schedules are set in stone, either. Further delays are possible for Artemis II, and likely for Artemis III if NASA sticks to the current mission plans.

Although the SLS rocket will be ready for the current schedule, barring a catastrophe, the other elements are in doubt. For Artemis II, NASA still has not cleared a heat shield issue with the Orion spacecraft. That must be resolved before the mission gets a green light to proceed next year. The challenges are even greater for Artemis III. For that mission NASA needs to have a lunar lander—which is being provided by SpaceX with its Starship vehicle—in addition to spacesuits provided by Axiom Space for the lunar surface. Both of these elements remain solidly in the development phase.

What Boeing is telling us indirectly is that, though NASA has not yet announced any further delays in those launch dates for Artemis-2 and Artemis-3, those dates are going to be delayed, quite possibly by one or more years.

None of this is a surprise. I have long been predicting that the first manned lunar landing in the Artemis program will not take place before 2030. In fact, that date was obvious the moment NASA announced its plan to make the Lunar Gateway space station an integral part of the program, back in 2018, when it was called LOP-G.

Now that SLS development is complete and NASA considers it “operational”, Boeing is merely reducing the staffing to maintain its assembly line, reducing it accordingly because of expected delays when additional rockets will be needed.

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Technical issues with Lockheed Martin’s Orion capsule to delay next Artemis mission

9:20 am

It appears that technical issues with Lockheed Martin’s Orion capsule are one of the main reasons NASA has had to delay next Artemis mission, the first to put humans inside that capsule and then take them around the Moon.

In January 2024 it was reported that the mission would be delayed from a launch before the end of 2024 until 2025. We now know why:

NASA is working with Orion spacecraft prime contractor Lockheed Martin to resolve a handful of issues that came up late last year during ground testing, forcing the space agency to delay the launch readiness target date for its Artemis II circumlunar mission to September 2025. The Lockheed Martin assembly, test, and launch operations (ATLO) team at Kennedy Space Center (KSC) is reinstalling some electronics and implementing workarounds for others affected by an electrical circuit flaw found in digital motor controllers on the spacecraft.

While a resolution to that issue appears to be getting closer, the Orion program and contractor teams are also working through the corrective actions process for a problem with how the Orion batteries handle the shock of an extreme abort case.

In other words, Lockheed Martin discovered these two electrical issues only last year, after spending almost two decades and more than $15 billion developing Orion.

As I predicted in January, “None of these dates will be met. I predict that further delays will be announced next year and the year after that, pushing all these missions back again, in small increments.” I also predicted that NASA will be lucky to land a human on the Moon by 2030, a mere fifteen years after its original target date of 2015, set by George Bush Jr. in 2004.

In the meantime, expect SpaceX’s Starship to begin regularly commercial and governmental flights to the Moon in the next five years. Long before SLS and Orion put humans on the Moon, Starship will be doing it privately for less cost.

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NASA makes it official: The entire Artemis schedule is delayed

9:17 am

Surprise! NASA yesterday officially confirmed the rumors reported earlier about delays in its Artemis Moon program, outlining a new schedule that pushes all the launches back from months to more than a year.

NASA will now target September 2025 for Artemis II, the first crewed Artemis mission around the Moon, and September 2026 for Artemis III, which is planned to land the first astronauts near the lunar South Pole. Artemis IV, the first mission to the Gateway lunar space station, remains on track for 2028.

The agency cited issues with its Orion capsule that need fixing, including unexpected damage to its heat shield during the first test flight in 2022, battery problems found during ground testing, and new issues discovered with the as-yet unflown environmental systems designed to keep the astronauts alive.

One rumor that did not turn out to be true was the suggestion that first manned lunar landing would be shifted from Artemis 3 to Artemis 4, to give NASA more time to test things.

More details about the press briefing can be found here.

No one should take any of these dates seriously. NASA technique for announcing delays in this moon program have consistently been wrong. It announces small delays incrementally, to hide the fact that it knows the actual launch will be delayed far more that politics allows. The program was first proposed in 2004 with a planned landing in 2015. Since then NASA has announced numerous delays numerous times, always in small amounts. Yet by 2015 it was clear the first landing wouldn’t happen for at least a decade (after a decade of work), because of Obama’s unilateral cancellation of the initial program and Congress’s demand that it be re-established in a different form. By 2022 it was clear that the first manned landing mission was at least five years away.

Thus these new dates will certainly slip. You can bet on it. As I noted yesterday, NASA will be lucky to make that first manned lunar landing by 2030.

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Japan & NASA negotiating plan to put Japanese astronaut on later Moon landing mission

3:15 pm

According to the Japanese press, Japanese and American government officials are negotiating a plan to include a Japanese astronaut on one of the later Artemis Moon landing missions, presently hoping to fly in the late 2020s.

Japan has been negotiating with the United States, aiming for its first landing on the moon in the late 2020s. Tokyo and Washington will establish and sign an agreement on the activities of Japanese astronauts on the moon as early as next month, according to several government sources.

These stories are likely linked to the blather from Vice President Harris last week saying the U.S. will fly an international astronaut to the Moon before the end of the decade. At the time NASA officials would not confirm her statement, other than to say that NASA had agreed to fly European, Canadian, and Japanese astronauts to its Lunar Gateway station as part of its Artemis lunar program.

Several important details must be noted. First, the schedule for Artemis, as designed by NASA using SLS, Orion, Lunar Gateway, and Starship, is incredibly optimistic. The first manned mission is presently scheduled for 2025, but no one believes that date, including many at NASA. It will likely slip to 2026 or even 2027.

Second, the program is very fluid, and could undergo major changes with a new administration, especially because of the high cost of SLS. Once Starship/Superheavy is flying, at a cost expected to less than 1% of SLS, with an ability to fly frequently instead of once every two or three years, a new government might scrap the entire Artemis program as designed. A shift from SLS to Starship entirely might actually increase the number of astronauts going to the Moon, both from the U.S. and the entire Artemis Accords alliance.

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October 13, 2023 Quick space links

2:55 pm

Courtesy of BtB’s stringer Jay.

 

  • NASA’s inspector general agrees SLS is too costly and it will be impossible to reduce that cost

    • The report is available here [pdf]. Normally I’d highlight each new IG report that notes these plain facts, but I’ve grown bored with doing so. They (as well as I) have been saying the same thing time after time — going back to 2011 — but nothing ever changes. We keep pouring money into an SLS rocket that costs too much, can’t launch frequently, and in the end won’t accomplish much of anything, while other space projects of greater value (for much less) go by the wayside.

    And despite this report we shall continue to do so, because the federal government is broken utterly, from the White House down to the mail rooms in Congress and every agency in the executive branch. It has entirely abandoned its responsibilites to serve the American people. Instead its goal now is simply to funnel money to itself, even if that funnelling will bankrupt the country.

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Expect long delays after third Artemis mission

10:24 am

Link here. The article outlines from a different perspective the many problems faced by NASA’s Artemis program, specifically related to its SLS rocket.

First, that fourth Artemis mission will require a larger first stage, which is far behind schedule and should not be ready until late 2028 (though I predict at least one to two years beyond that date).

Second, that larger upper stage will require completion of a new mobile launcher platform, replacing the mobile launcher now in use that cost about a half billion and will only be used three times. The new launcher platform however is also behind schedule and overbudget. Its completion is not expected until 2027 (though I predict at least one year beyond that date).

Thus, even if the third Artemis mission flies in 2026, as presently scheduled, it will be at least two years before the fourth can fly, but more likely the gap will be three to four years.

Everything related to NASA’s SLS rocket is a mess. If the people running our government had brains, they would immediately dump it and do everything they can to speed development of Starship/Superheavy, which has a better design, is reusuable, is more powerful, has greater capabilities, and most important of all, will be able to fly frequently and quickly at a very low cost, something that SLS will never be able to do.

Unfortunately, the people running our government have no brains, or to be more precise, refuse to use them because of their own selfish petty interests. SLS will go on, wasting billions. And the effort to squelch Starship/Superheavy will also continue, because these petty federal officials can’t have a private company show them up. No way! It must be their way, or the highway!

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GAO blasts NASA for purposely failing to control the budget of its SLS rocket

10:21 am

In a new report [pdf] released yesterday, the Government Accountability Office (GAO) strongly blasted NASA’s non-budgeting process for financing the costs for this SLS rocket, which appear specifically designed to allow those costs to rise uncontrollably.

This one sentence from the report says it all:

NASA does not plan to measure production costs to monitor the affordability of the SLS program.

That non-plan is actually in direct defiance of four different reports by both the GAO and NASA’s inspector general over the past decade, all of which found that NASA was not using standard budgeting practices with SLS and which all demanded it do so forthwith. As this new report notes in reviewing this history, in every case NASA failed to follow these recommendations, and instead created budgetary methods designed to instead obscure the program’s cost.

This report notes that NASA continues to do so.
» Read more

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NASA engineers still struggling to understand why Orion’s heat shield ablated so much

9:10 am

NASA engineers still do not understand why the heat shield on its Orion capsule ablated as it did during its return to Earth on the first unmanned Artemis-1 mission.

The agency is still running tests. It also expressed confidence that the issue will not delay the Artemis-2 mission, the first intended to carry humans on SLS and in Orion and still scheduled for late 2024.

At the same time, agency officials hinted that the third Artemis mission, which has always been planned as putting humans on the Moon for the first time since Apollo, might not achieve that goal. It is still not clear whether the mission’s lunar spacesuits as well as SpaceX’s Starship lunar lander will be ready on time. The latter is facing serious regulatory problems imposed by the Biden administration that is generally preventing it from flight testing the spacecraft.

That second Artemis mission, the first planned to carry humans, is one that actually at present carries the most risk. It will not only use a heat shield that at present engineers do not entirely understand, it will be the first Orion capsule to have the environmental systems necessary for its human cargo. NASA is putting humans on the first test flight of those systems.

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ESA transfers its Artemis-2 Orion service module to NASA

9:18 am

The European Space Agency (ESA) yesterday officially handed over to NASA its second completed Orion service module, to be used in 2024 on the first manned Artemis mission, dubbed Artemis-2, that will carry four astronauts on a mission around the Moon.

The European Service Module-2 will power the Orion spacecraft on the Artemis II mission that will see NASA astronauts commander Reid Wiseman, pilot Victor Glover, and mission specialists Christina Koch with Canadian Space Agency astronaut Jeremy Hansen complete flyby of the Moon and return to Earth.

The crew will fly Orion to 8889 km beyond the Moon before completing a lunar flyby and returning to Earth. The mission will take a minimum of eight days and will collect valuable flight test data, in the first time for over 50 years that humans have voyaged to our natural satellite.

The odds of this launching in 2024 are relatively slim. It will also be the first time NASA will be flying Orion’s environmental systems (the systems that keep the astronauts alive). We all hope those system work perfectly this first time, since people will be on board.

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Boeing sued for stealing specialized tooling to assembly SLS

9:36 am

A Colorado company, Wilson Aerospace, on June 6, 2023 filed a lawsuit against Boeing, claiming that the company conspired with Wilson’s direct competitors to steal the designs of its specialized tool for installing the core station engines on SLS.

According to the lawsuit, after some initial discussions, Boeing arranged for a “live” demonstration of Wilson’s torque device, during which participants could handle and operate it to verify the tool’s capability and performance. What Wilson claims it did not realize, however, is that some of the participants in this demonstration were not Boeing employees. “Wilson later learned that at least seven of those in attendance for the live presentation were external to Boeing and were, at the time, employees of Wilson’s direct competitors,” the lawsuit states. “This fact was concealed from Wilson who was deceived by Boeing and the ‘Bogus Boeing Employees’ into giving the presentation by falsely suggesting to Wilson that everyone was a Boeing employee.”

The complaint alleges that Boeing subsequently used information from this demonstration, as well as proprietary drawings and designs, to work with Wilson’s competitors to develop a cheaper solution. “Boeing concealed these facts from Wilson as part of its scheme to defraud Wilson and to transmit Wilson’s IP to its direct competitors,” the lawsuit states.

The company is demanding a jury trial. If its charges are proved true, it will be another piece of evidence demonstrating the level of corruption that exists at Boeing.

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NASA inspector general finds more cost overruns in the agency’s SLS rocket program

10:12 am

Surprise! Surprise! A new NASA inspector general report [pdf] has found that the agency’s SLS rocket program is continuing to experience cost overruns and mismanagement that are “obscene”, as noted in this news report.

An independent report published Thursday contained troubling findings about the money spent by the agency on propulsion for the Space Launch System rocket. Moreover, the report by NASA Inspector General Paul Martin warns that if these costs are not controlled, it could jeopardize plans to return to the Moon.

Bluntly, Martin wrote that if the agency does not rein in spending, “NASA and its contracts will continue to exceed planned cost and schedule, resulting in a reduced availability of funds, delayed launches, and the erosion of the public’s trust in the agency’s ability to responsibly spend taxpayer money and meet mission goals and objectives—including returning humans safely to the Moon.”

Things are really much worse than this, mostly because it appears the Marshall Space Flight Center that runs the SLS program for NASA uses cost-plus contracts, which are essentially a blank check for contractors to run up costs endlessly, all of which the government must cover, and allows the process to go over-schedule against its own regulations. Furthermore, the cost overruns are for rockets and engines that are not newly developed, but in use for decades by Northrop Grumman and Aerojet Rocketdyne.

Note that this really isn’t news. Anyone with any intellectual honesty at all will know that every aspect of SLS and Orion is mismanaged and will go over budget and behind schedule endlessly. These problems are not a bug, however, but a feature of the system. The goals of SLS and Orion are not really to build a rocket to explore the solar system but to create an endless jobs program in congressional districts here on Earth. This misguided approach meanwhile robs America of a viable space effort because the money wasted could have actually been used to jumpstart a viable and competitive space-faring economy that actually achieves something.

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Aerojet Rocketdyne wins contract from Lockheed Martin to build more Orion engines

8:22 am

Aerojet Rocketdyne announced yesterday that it has been awarded a new $67 million contract from Lockheed Martin to build the Orion propulsion engines for Artemis missions six though eight.

This contract option includes delivery of three additional sets of Orion’s service module auxiliary engines and three additional jettison motors. The eight auxiliary engines each produce 105 pounds of thrust to help maintain Orion’s in-space trajectory and position, and supplement the Orion Main Engine. The jettison motor, located on Orion’s Launch Abort System (LAS), generates 40,000 pounds of thrust to separate the LAS from the crew module during both nominal operations and abort scenarios, allowing the spacecraft to continue on its journey. The jettison motor is the only motor on the LAS that fires during every mission.

These Artemis missions are not expected to occur until very late in this decade, by which time Starship will likely be making regular commercial trips to the Moon. At that time Orion will look increasingly ridiculous next to Starship, and will demonstrate starkly the difference in what government can do versus a free private sector.

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Post-Artemis-1 report: heat shield ablated more than expected; power system issued unexpected commands; damage to launchpad

8:56 am

In a March 7, 2023 briefing, NASA officials provided an overall report of what happened during the first SLS launch, noting that there were some minor engineering issues but none that appeared to them significant.

The biggest issue of note was the Orion heat shield.

Howard Hu, Orion program manager at NASA, said that material on the heat shield had ablated differently than what engineers expected from ground tests and computer models. “We had more liberation of the charred material during reentry than we had expected,” he said. Engineers are just beginning detailed analysis of the heat shield to determine why it behaved differently than expected.

The amount ablated was well within safety margins, but engineers still do not understand why the material behaved differently than expected.

Engineers are also trying to understand why the power system of the Orion service module issued unplanned commands, several times opening what officials called a “latching current limiter.” This action caused no problems to the capsule’s operations, but it is concerning it occurred.

The launch also did more damage to the mobile launcher tower than expected.

According to NASA officials, none of these issues will delay the planned November 2024 launch date for the Artemis-2 mission, the first intended to carry humans.

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Update on the ten cubesats launched by SLS

9:16 am

Link here.

At this moment six of the ten cubesats either accomplished their mission successfully or are still operating, while four cubesats failed entirely.

Of those still working, two will go into lunar orbit and try to find evidence of both hydrogen and ice on the Moon. A third is testing “solid iodine” thrusters, while a fourth will observe how yeast samples react to a long exposure in deep space. A fifth cubesat is a joint NASA-JAXA mission, and is testing how to fly a smallsat in the low gravity of a Lagrangian point.

Finally, an Italian cubesat was used to successfully take images of the Moon and Orion, and has completed its mission.

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Orion successfully splashes down in the Pacific

8:42 pm

NASA’s Orion capsule today successfully returned from a three week trip around the Moon, splashing down in the Pacific where it was successfully recovered.

The next Artemis flight will be a manned one, using SLS and Orion to fly around the Moon. It will also be the first time Orion will use its full environmental system, with humans on board. Though presently scheduled for May 2024, it is almost certainly not going to fly before 2025.

The actual Artemis manned lunar landing will follow, no sooner than two years after that. As presently designed, that mission requires the establishment of the Lunar Gateway station — astronauts can be transferred from Orion to Starship and back again, and that station is likely not going to be ready in this time frame.

As I said yesterday, I predict the two already purchased private Starship missions around the Moon, paid for by Yusaku Maezawa and Jared Isaacman, will happen first. Both will certainly beat NASA’s planned landing on the Moon. I also expect both to beat that Orion manned fly-around in ’24-’25. And each will cost pennies compared to the entire SLS/Orion program, while actually making a profit that will be used to further development and more manned private flights.

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NASA extends Boeing’s contract to produce more SLS rockets

10:30 am

NASA yesterday announced that it will pay Boeing $3.2 billion for two more SLS rockets.

NASA has finalized its contract with Boeing of Huntsville, Alabama, for approximately $3.2 billion to continue manufacturing core and upper stages for future Space Launch System (SLS) rockets for Artemis missions to the Moon and beyond.

Under the SLS Stages Production and Evolution Contract action, Boeing will produce SLS core stages for Artemis III and IV, procure critical and long-lead material for the core stages for Artemis V and VI, provide the exploration upper stages (EUS) for Artemis V and VI, as well as tooling and related support and engineering services.

All this really means is that NASA is going depend on SLS and Orion to fly its astronauts to and from the Moon, and because of that its pace of flight will be — at best — slow and long-drawn out. For example, this new order extends the contract out to 2028. It will thus leave plenty of time for SpaceX and other nations to get there first.

I predict that the private Starship missions paid for by Yusaku Maezawa and Jared Isaacman will both fly before these two new Artemis missions. You heard it here first.

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Orion completes burn to send spacecraft back to Earth

8:50 am

NASA’s Orion capsule yesterday successfully fired its engines as it zipped past the Moon to send it on a trajectory back to Earth, with splashdown in the Pacific off the coast of California scheduled for December 11, 2022.

Not all was hunky-dory, however. Prior to the burn a power unit shut down unexpectedly.

A power unit on board the Orion spacecraft turned off four devices “responsible for downstream power” that connect to the Artemis 1 vehicle’s propulsion and heating subsystems, NASA officials wrote in a statement. But mission personnel swiftly put a fix in place and the mission is carrying on, the statement emphasized. “Teams confirmed the system was healthy and successfully repowered the downstream components,” agency officials wrote in the statement, released late on Sunday. “There was no interruption of power to any critical systems, and there were no adverse effects to Orion’s navigation or communication.”

Engineers think the shut down was related to a test performed in connection with an earlier incident.

Regardless, all now appears well for that December 11nd splashdown.

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Orion fires engine, leaves lunar orbit

8:47 am

After firing its engines yesterday, NASA’s Orion spacecraft has left lunar orbit and begun a long looping route that will zip past the Moon and then head back to Earth.

The burn changed Orion’s velocity by about 454 feet per second and was performed using the Orion main engine on the European Service Module. The engine is an orbital maneuvering system engine modified for use on Orion and built by Aerojet Rocketdyne. The engine has the ability to provide 6,000 pounds of thrust. The proven engine flying on Artemis I flew on 19 space shuttle flights, beginning with STS-41G in October 1984 and ending with STS-112 in October 2002.

The burn is one of two maneuvers required ahead of Orion’s splashdown in the Pacific Ocean on Dec. 11. The second will occur on Monday, Dec. 5, when the spacecraft will fly 79.2 miles above the lunar surface and perform the return powered flyby burn, which will commit Orion on its course toward Earth.

The spacecraft will splashdown on December 11, 2022, if all goes right.

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Six of the ten cubesats launched toward the Moon by SLS still working

9:46 am

The Moon as seen by ArgoMoon
Click for full image.

Of the ten cubesats launched toward the Moon by SLS last week, six are still working while four have problems that are likely killing their missions.

The photo to the right, cropped, reduced, and sharpened to post here, was taken by ArgoMoon, an Italian cubesat that is working perfectly. The large impact basin visible is Orientale Basin, located just on the edge of the visible face of the Moon but partly hidden on the far side.

A summary of the status of all ten can be found here. Of the other five still functioning properly, all have been able to maintain proper communications.

Possibly the biggest disappointment however is the failure of Japan’s Omotenashi lander, which was going to attempt a lunar soft landing. Shortly after launch it began tumbling, and engineers were never able to regain full control or communications. The landing attempt has now been abandoned.

Side note: Orion itself also captured some images as it zipped past the Moon yesterday, but they do not appear as high quality as ArgoMoon’s pictures.

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Ten cubesats released by SLS on way to Moon; one has problems

9:53 am

Shortly after SLS’s upper stage completed its engine burn to send Orion to the Moon, it separated and then successfully released ten cubesats on their own deep space missions.

These CubeSats will fly to various destinations including the Moon, asteroids, and interplanetary space. They will study various facets of the Moon and interplanetary travel, ranging from navigation techniques to radiation and biology. One of them is even planned to conduct a soft landing on the lunar surface.

Because of SLS’s numerous delays, there was a chance that many of these cubesats would lose the charges on their batteries and not function after launch. According to the article at the link, communications with six of these cubesats has been established.

The last cubesat above, from Japan and dubbed Omotenashi, was designed as a demonstration test. According to Japan’s space agency, JAXA, however, communications with the spacecraft are “unstable.”

Japan’s space agency said Thursday it has been unable to establish stable communication with the country’s mini moon lander launched on a U.S. rocket the previous day along with a mini satellite. The Japan Aerospace Exploration Agency said it is now trying to control the position of the Omotenashi lander, adding its system of automatically turning to the Sun to gain solar power appears to be not functioning.

Before launch JAXA had rated the mission’s chances of success at 60%, but that mostly referred to the lunar landing. Though intended as a demo mission, it will be unfortunate if it fails for these reasons this early in the mission.

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NASA’s SLS rocket successfully launches Orion toward the Moon

12:26 am

After almost eighteen years of development and almost sixty billion dollars, NASA tonight finally completed the first unmanned test launch of its Space Launch System (SLS) rocket, lifting off at 1:41 am (Eastern).

The two solid rocket boosters functioned as planned, separating from the core stage with no problem. Then core stage and its four former shuttle engines completed its burn, putting the capsule and its upper stage into Earth orbit, and then separated cleanly. At about 30 minutes after launch the service module’s solar arrays completed their deployment. At 53 minutes after launch a 30 second burn circularized the orbit in preparation for the trans-lunar-injection (TLI) burn that will send Orion to the Moon. TLI occurred about 90 minutes after launch, after a period of check-out in orbit.

Orion will spend 26 days in space, about a week of which will be in a wide lunar orbit, testing its systems. If all goes right it will splashdown on around December 11th.

As this was the first U.S. government launch in more than a decade, since 2011 when the space shuttle was retired, the leader board for the 2022 launch race remains unchanged:

The leaders in the 2022 launch race:

52 SpaceX
51 China
19 Russia
9 Rocket Lab
8 ULA

The U.S. now leads China 76 to 51 in the national rankings, and trails the rest of the world combined 79 to 76.

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Watching the first SLS launch tonight

9:25 am

At this moment, with weather 90% favorable and the countdown underway, the first launch of NASA’s SLS rocket appears go for a 1:04 AM (Eastern) launch tonight.

You can watch the live stream on NASA TV here, which will begin at 3:30 pm today and mostly be NASA propaganda intermixed with descriptions of the rocket, its payloads, its full mission, and updates on the launch countdown.

NASA’s live stream is now embedded below, beginning at 10:30 PM (Eastern) when actual coverage of the final countdown begins. I would still suggest that you wait until at least 12:30 AM (Eastern) before watching, as those first two hours will still be filled with a lot of NASA propaganda blather.
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NASA managers okay SLS launch attempt November 16th

7:39 pm

NASA managers have given the go-ahead to the scheduled launch of the agency’s SLS rocket for 1:04 am (Eastern) on November 16, 2022, despite the existence of some detached caulking that Hurricane Nicole had pulled free.

Engineers examined detailed analysis of caulk on a seam between an ogive on Orion’s launch abort system and the crew module adapter and potential risks if it were to detach during launch. The mission management team determined there is a low likelihood that if additional material tears off it would pose a critical risk to the flight.

Technicians also completed replacing a component of an electrical connector on the hydrogen tail service mast umbilical. While swapping the component did not fully fix the issue, engineers have redundant sources of information supplied through the connector.

The launch window is two hours long. As this is a night launch, it will be quite spectacular, no matter what happens. I will embed the live stream tomorrow in the early evening, for those who wish to watch NASA’s multi-hour propaganda stream. My suggestion would be to find a better use of your time until around 12:50 am (Eastern). Then would be a good time to tune in.

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SLS launch early on November 16th remains uncertain

8:47 am

Despite repeated assurances that the November 16, 2022 1:04 am (Eastern) launch of NASA’s SLS rocket remains on target, managers have also noted that damage to a small piece of caulking at the base of the shroud protecting the Orion capsule remains an issue that could cause a scrub.

But high winds from Nicole caused a thin strip of caulk-like material known as RTV to delaminate and pull away from the base of the Orion crew capsule’s protective nose cone at the top of the rocket. The material is used to fill in a slight indentation where the fairing attaches to the capsule, minimizing aerodynamic heating during ascent. The fairing fits over the Orion capsule and is jettisoned once the rocket is out of the dense lower atmosphere. “It was an area that was about 10 feet in length (on the) windward side where the storm blew through,” said mission manager Mike Sarafin. “It is a very, very thin layer of RTV, it’s about .2 inches or less … in thickness.”

Engineers do not have access for repairs at the pad and must develop “flight rationale,” that is, a justification for flying despite the delaminated RTV, in order to proceed with the launch. Managers want to make sure any additional material that pulls away in flight will not impact and damage downstream components.

In plain language, NASA managers would either have to issue a waiver that says this small piece of caulking poses no risk, or scrub and roll the rocket back to the assembly building to fix it. The second option would delay the launch another month, at a minimum.

A waiver however would continue NASA’s pattern with the shuttle (and continuing with SLS) to dismiss potential engineering problems simply to avoid schedule delays. With the shuttle, this pattern twice caused the loss of a shuttle and crew. With SLS, NASA has already waived by more than a year its rules concerning the stacked life of the rocket’s solid-fueled boosters. Agency managers have also waived the full test requirements from the dress rehearsal countdown, so that this test did not test everything it should.

It is expected that NASA managers will announce the waiver today on this problem. Whether it matters when the rocket goes through maximum dynamic pressure shortly after lift-off will likely determine the future of SLS.

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SLS rides out hurricane; engineers now assessing damage

9:00 am

NASA’s SLS rocket has apparently successfully survived on the launchpad the hurricane-force winds from Nicole, though engineers will need to inspect the rocket to see if there is any less obvious damage that might delay the now scheduled November 16th launch.

With blastoff on a long-delayed maiden flight on tap next week, sensors at pad 39B recorded gusts as high as 100 mph atop a 467-foot-tall lightning tower near the rocket. But winds at the 60-foot-level, which are part of the booster’s structural certification, peaked at 82 mph, just below the 85 mph limit.

The observed winds were “within the rocket’s capability,” said Jim Free, manager of exploration systems at NASA headquarters. “We anticipate clearing the vehicle for those conditions shortly.”

“Our team is conducting initial visual check outs of the rocket, spacecraft and ground system equipment with the cameras at the launch pad,” he tweeted. “Camera inspections show very minor damage such as loose caulk and tears in weather coverings. The team will conduct additional on-site walk down inspections of the vehicle soon.”

If no issues are found, the countdown will begin on November 14th.

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SLS launch delayed until November 16

3:57 pm

In order to give them time to make sure all is right after the coming tropical storm, NASA managers have decided to delay the first test flight of SLS two days until November 16.

A launch during a two-hour window that opens at 1:04 a.m. EST on Nov. 16 would result in a splashdown on Friday, Dec. 11. If needed, NASA has a back-up launch opportunity on Saturday, Nov. 19, and will coordinate with the U.S. Space Force for additional launch opportunities.

At the moment they have decided to keep the rocket on the launchpad, as they expect it will be able to withstand the predicted storm. If the predictions change however they still have the option to roll it back into the assembly building.

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Hurricane threatens SLS on launchpad

8:53 pm

A storm, now rated subtropical, that is expected to cross the east coast of Florida on November 10th with the possibility that it could strengthen into a hurricane now threatens NASA’s SLS rocket that is on its Florida launchpad preparing for its first test flight on November 14, 2022.

A map of the storm’s presently predicted track can be seen here.

NASA’s Kennedy Space Center in Florida is currently in a HURCON (Hurricane Condition) IV status, which includes implementing checklists and preparations for the storm as the agency continues to prioritize its employees in the Kennedy area. Based on current forecast data, managers have determined the Space Launch System rocket and Orion will remain at Launch Pad 39B. Teams at Kennedy will continue to monitor the weather, make sure all personnel are safe, and will evaluate the status of the Monday, Nov. 14, launch attempt for the Artemis I mission as we proceed and receive updated predictions about the weather.

Depending on the storm’s track in the next 24 hours, as well as its strength, NASA managers have the option of returning the rocket to the assembly building to protect it. If they do so, however, it is certain the November 14th launch date will be scrubbed. As they have a window of a number of additional dates [pdf] through November 27th, I suspect they will then aim for one of those dates.

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