Tag: SLS

Blue Origin announces plans to upgrade New Glenn to match SLS

12:25 pm

New Glenn compared to the Saturn-5
Graphic issued by Blue Origin’s CEO comparing
New Glenn to the Saturn-5. Click for source.

In an update posted today, Blue Origin announced that it is planning to begin upgrades to its New Glenn orbital rocket as soon as its very next launch early in 2026, with those upgrades eventually raising the rocket’s capabilities to that of NASA’s overpriced, cumbersome, and poorly designed SLS rocket.

One of the primary enhancements includes higher-performing engines on both stages. Total thrust for the seven BE-4 booster engines is increasing from 3.9 million lbf (17,219 kN) to 4.5 million lbf (19,928 kN). BE-4 has already demonstrated 625,000 lbf on the test stand at current propellant conditions and will achieve 640,000 lbf later this year, with propellant subcooling increasing the current thrust capability from the existing 550,000 lbf.

The total thrust of the two BE-3Us powering New Glenn’s upper stage is increasing from the original design of 320,000 lbf (1,423 kN) to 400,000 lbf (1,779 kN) thrust over the next few missions. BE-3U has already demonstrated 211,658 lbf on the test stand.

These numbers are a little more than half that put out by the Saturn-5 in the 1960s. New Glenn however has a reusable first stage, so it will cost far less to launch, and will be able to do so frequently. These changes will also make it comparable to SpaceX’s Falcon Heavy.

These engine upgrades however are only a start. Blue Origin also plans to offer a second more powerful version of New Glenn by adding two BE-4 engines to the first stage and two BE-3U engines to the upper stage.
» Read more

40 comments

NASA now targeting a February-to-April launch window for first manned Artemis mission

9:43 am

Orion's damage heat shield
Damage to Orion’s heat shield caused during re-entry in 2022,
including “cavities resulting from the loss of large chunks”.
Nor has this issue been fixed.

According to a NASA official at an event yesterday, the agency is now targeting launch window starting on February 5, 2026 and extending into April for the first manned Artemis mission, dubbed Artemis-2, that will slingshot four astronauts around Moon and back to Earth on a 10-day-flight.

If Artemis 2 does lift off on Feb. 5, it will be at night, NASA officials said. The space agency has about five days apiece in February, March and April to launch the flight. The latest possible date is April 26, according to NASA. NASA will aim to hit the earlier part of that launch window, Hawkins said, but she stressed that crew safety will drive the timeline.

That mission will fly with an Orion capsule that has safety concerns, including a questionable heat shield (see picture above) and an untested environmental system.

Meanwhile, as part of NASA’s never-ending PR effort to sell the mission, it announced today that the mission’s four astronauts have now given their Orion capsule a name, Integrity.

The name Integrity embodies the foundation of trust, respect, candor, and humility across the crew and the many engineers, technicians, scientists, planners, and dreamers required for mission success.

Considering NASA’s level of dishonesty during the entire development of SLS and Orion, the ironies of this name and these claims is quite breath-taking.

6 comments

The word that best describes our present NASA lunar program is “delusional.”

12:16 pm

Artemis, a program based on fantasy
Artemis, a program based on fantasy

Increasingly it appears everyone in Congress, the White House, and NASA, as well as our bankrupt mainstream press, has become utterly divorced from reality in talking about NASA’s Artemis lunar program. The claims are always absurd and never deal with the hard facts on the ground. Instead, it is always “Americans are piorneers! We are great at building things! We are going to beat China to the Moon!”

An interview of interim NASA administration (and Transportation secretary) Sean Duffy yesterday on the Sean Hannity Show made all these delusions very clear. First Hannity introduced Duffy by stating with bald-faced ignorance that “NASA has a brand-new program. It is called Artemis that aims to get astronauts back on the Moon in the next couple of years.”

I emphasize “brand-new” because anyone who has done even two seconds of research on the web will know that Artemis has existed now for more than a decade. Hannity illustrates his incompetence right off the bat.

Duffy then proceeds to insist that the next Artemis mission, dubbed Artemis-2, will fly in April 2026 and send four astronauts around the Moon, followed by the Artemis-3 manned landing one year later.

Being an incompetent member of the propaganda press, Hannity of course accepts these claims without question. He fails to question Duffy about the serious issues with the Orion heat shield, which experienced extensive unexpected damage that is still not understood during its return on the first Artemis mission in 2022.

Nor does either Duffy or Hannity mention the fact that for Artemis to land humans on the Moon SpaceX’s Starship not only has to become operational for human passengers, it needs an in-orbit refueling capability that does not yet exist. I have full confidence that SpaceX will eventually succeed in achieving these benchmarks, but I also doubt it will be able to do it by mid-2027, as claimed by Duffy.

Duffy and Hannity however are not alone in living in this dream world. » Read more

36 comments

Senate reconciliation budget bill includes Cruz’s big spending additions to NASA

9:36 am

Senate NASA budget increases

According to a tweet yesterday by Representative Marjorie Taylor Greene (R-Georgia), the reconciliation budget bill that was passed by the Senate included the budget additions that Senator Ted Cruz (R-Texas) had proposed to save SLS, Orion, and Lunar Gateway.

The graphic to the right lists these budget numbers. It is not clear whether the launch taxes on payloads that Cruz proposed were also included, though likely not based on the rules under which the reconciliation bill was passed.

This additional money for these projects contradicts directly the NASA 2026 budget proposal put forth by Trump that aimed to cancel Lunar Gateway and end SLS and Orion after only two more flights. Their existence in this passed Senate bill suggests that Congress is cool with the idea of spending this money and continuing these projects, even though they do nothing but waste taxpayer money and get us no where in space.

It also appears from the language in the graphic that the Senate is eager to also spend more money on NASA’s Mars sample return project, even though NASA itself still has no idea how to accomplish the task.

9 comments

Nozzle blows off of Northrop Grumman SLS solid rocket booster during static fire test

1:05 pm

During a static fire test of a new upgraded strap-on solid-fueled booster to be used on the second version of NASA’s SLS rocket, it appears the nozzle broke off near the end of the test.

I have embedded the video below.

This failure is not good for getting the upgraded version of SLS built, dubbed Block 2. Block 1 has flown once unmanned, and is planned for the next two manned missions. Block 2 would be for further manned missions beyond that. The Trump administration has proposed cancelling it, ending SLS after those two Block 1 flights. Senator Ted Cruz (R-Texas) has instead introduced a bill that would save it in order to fly two Block 2 SLS manned missions.

This failure is definitely going to delay and add cost to Block 2 development, a program that is already over budget many times over and a decade-plus behind schedule. These additional delays and cost overruns are not going to help it politically. It justifies the Trump administration’s desire to cancel it.

Moreover, this nozzle failure suggests a very fundamental design problem. Northrop Grumman, which built and was testing this booster, also builds the solid-fueled strap-on boosters used on ULA’s Vulcan rocket, which had a similar nozzle failure during Vulcan’s second launch in October last year. Both Northrop Grumman and ULA have said they had identified and fixed the cause of that failure, and the military has certified it for operational launches, but nonetheless Vulcan still remains sidelined, more than eight months later.

I suspect ULA is going to have to do more testing of the Northrop Grumman Vulcan side boosters before its next Vulcan launch, delaying that rocket further.
» Read more

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Senate schedules vote for confirming Jared Isaacman as NASA administrator

2:48 pm

The Senate is now targeting early June for its vote on Jared Isaacman’s nomination as NASA administrator.

Senate Majority Leader John Thune (R-S.D.) filed cloture on Isaacman’s nomination May 22, a procedural move that would set up a vote on the nomination in early June. The Senate is not in session the week of May 26 because of the Memorial Day holiday.

Since his nomination was approved by the Senate Commerce committee in April, Isaacman has been meeting with many other senators. The article at the link does the typical mainstream press thing of pushing back 100% against the proposed NASA cuts put forth by Trump’s 2026 budget proposal, telling us that these senators were generally opposed to those cuts and questioning Isaacman about them, a claim not yet confirmed. It did note something about those senators and those proposed cuts that if true was very startling and possibly very encouraging.

While many of the proposals in the budget, like winding down SLS and Orion, were expected, the scale of the cuts, including a nearly 25% overall reduction in NASA spending, still took many by surprise. [emphasis mine]

In other words, Congress was not surprised by the proposed end of SLS and Orion. It even appears they are ready to give it their stamp of approval.

None of this is confirmed, so take my speculation with a grain of salt. Still, the winds do appear to be blowing against SLS and Orion.

2 comments

Congress: Let’s throw some more astronaut lives away so we can preen for the camera!

2:48 pm

Jared Isaacman
Jared Isaacman

Here we go again: As I noted yesterday, the hearing this week of Jared Isaacman, Donald Trump’s nomination to become NASA’s next administrator, revealed almost nothing about what Isaacman plans to do once confirmed by the Senate. He very carefully kept his options open, even while he strongly endorsed getting Americans on the Moon as fast as possible in order to beat the Chinese there. When pressed by senators from both parties to commit to continuing the SLS, Orion, and Lunar Gateway projects to make that happen, Isaacman picked his words most cautiously. He noted that at the moment that plan seemed the best for getting to the Moon first. He also noted repeatedly that this same plan is years behind schedule and overbudget.

Like any smart businessman, Isaacman knows he cannot make any final decisions about SLS, Orion, or Gateway until he takes office and can aggressively dig into the facts, as administrator. He also knew he could not say so directly during this hearing, for to do so would antagonize senators from both parties who want those programs continued because of the money it pours into their states. So he played it coy, and the senators accepted that coyness in order to make believe they were getting what they want.

But what do these senators want? It appears our politicians (including possibly Trump) want NASA to launch humans to the Moon using SLS and Orion and do so as quickly as possible, despite knowing that both have real engineering issues of great concern. Instead, our elected officials want politics to determine the lunar flight schedule, instead of engineering, the same attitude that killed astronauts on Apollo 1 in 1967, on Challenger in 1986, and on Columbia in 2003. The engineering data then said unequivocally that things were not safe and that disaster was almost guaranteed, but NASA and Congress demanded the flights go on anyway, to serve the needs of politics.

With SLS and Orion it is now the same foolishness all over again. » Read more

20 comments

Boeing announces a new round of layoffs related to its SLS NASA contract

9:02 am

Boeing yesterday announced that it will layoff another 71 employees in connection with its SLS NASA contract, based on rumored changes in NASA’s entire Artemis lunar program, including the increasingly real possibility that SLS will be canceled entirely by the new Trump administration.

The defense contractor was already in the midst of reducing its workforce, including in Alabama. But today, the company told AL.com that changes to its contract with NASA to develop the Space Launch System program sparked the need for some of the 71 layoffs. “As Boeing and NASA continue to finalize contract revisions for Boeing’s work on the Space Launch System program, we have successfully mitigated a majority of the previously announced workforce reductions,” a Boeing spokesperson said in an email to AL.com.

The news article at the link actually suggests that the total number of layoffs is now half that predicted by the company a few weeks ago, so it remains very unclear if these layoffs are because NASA is considering cancelling SLS, or because Boeing is simply shifting SLS management from development (which requires more people) to routine operations.

One comment

Boeing notifies SLS employees of impending layoffs

11:04 am

The real cost of SLS and Orion
The expected real per launch cost of SLS and Orion

Boeing yesterday sent a notice out to its employees working on NASA’s SLS rocket that up 400 could be laid off due to “revisions to the Artemis program and cost expectations.”

Boeing SLS employees were informed Feb. 7 that the company was making preparations to cut up to 400 jobs from the program because of “revisions to the Artemis program and cost expectations.” The specific positions being considered for elimination were not announced but would account for a significant fraction of the overall SLS workforce at the company.

This is probably the most significant update from the entire SLS program since it was first proposed by George Bush Jr in 2004. All other announcements either told us there were going to be more delays, the cost was going up, or there were newly discovered technical problems caused by bad management or sloppy work. This announcement instead actually indicates that NASA management — under pressure from the new Trump administration — is finally addressing these failures after two decades.

In the past few months there have been many indications from the swamp in Washington that it is finally beginning to recognize the absurdity and stupidity of the whole SLS/Orion infrastructure, a realization I outlined in detail fourteen years ago, soon after the project was reshaped from the absurd and stupid Ares project under Bush Jr. to SLS/Orion under Obama.

It took however the arrival of Trump (changed himself from his first administration) to do it. Trump is doing what no president has done in our lifetimes, going through all federal programs and ripping them apart if they are failing to do what they promise. And he is doing it with full and amazingly enthusiastic support of the American people. No one cares that government employees are “crying.” Nor does anyone pay attention any longer to these sob stories, put out by the propaganda press. It have proven itself to be habitual liars whose only interest has been prop up the Washington swamp, and everyone now recognizes it.

Expect a major reshaping of NASA and its entire manned program. We will still be heading to the stars, but finally doing it.

8 comments

More evidence SLS and Orion are on the way out

11:12 am

An article today by a local Fox station in Orlando calling NASA’s decision to fly the next Artemis mission using the Orion capsule as a return to the bad culture that caused both shuttle accidents is strong evidence that the political winds are now definitely blowing against the future of both NASA’s SLS rocket and its Orion capsule.

The article interviews former NASA astronaut Charles Camarda, who expressed strong reservations about NASA’s willingness to make believe the failures of the Orion heat shield on its only test flight could be dismissed.

“The way they’re attacking the problem is echoes of Challenger and Columbia, using exactly the same bad behaviors to understand the physics of the problem,” [former astronaut Charles Camarda] said. “They’re not using a research-based approach.” Camarda worries NASA is pressing ahead with the current heat shields because he says “a lot of the engineers are afraid to speak up, and that’s a serious problem.”

The point is not the article itself, but that a mainstream propaganda news outlet is publishing this perspective. This fact suggests that there is a growing willingness within the political community to end both SLS and Orion, and articles such as this are used to strengthen that narrative. Politicos in DC have a great fear of canceling big projects, and for them to agree to do so requires a great deal of groundwork to make sure the public will accept the decision. Articles such as this one are thus published in the propaganda press for exactly this reason.

In other words, the Washington swamp has now begun its own campaign to cancel SLS and Orion.

6 comments

Why Orion’s heat shield problems give Jared Isaacman the perfect justification to cancel all of SLS/Orion

9:43 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”

In yesterday’s press conference announcing new delays in NASA’s next two SLS/Orion Artemis missions to the Moon, agency officials were remarkably terse in providing details on why large chunks of Orion’s heat shield material broke off during its return to Earth in 2022 during the first Artemis mission. That damage, shown to the right, is one of the main reasons for the newly announced launch delays.

All they really said was that the damage was caused during re-entry, the atmosphere causing more stress than expected on the heat shield.

Today NASA finally released a more detailed explanation.

Engineers determined as Orion was returning from its uncrewed mission around the Moon, gases generated inside the heat shield’s ablative outer material called Avcoat were not able to vent and dissipate as expected. This allowed pressure to build up and cracking to occur, causing some charred material to break off in several locations.

…During Artemis I, engineers used the skip guidance entry technique to return Orion to Earth. … Using this maneuver, Orion dipped into the upper part of Earth’s atmosphere and used atmospheric drag to slow down. Orion then used the aerodynamic lift of the capsule to skip back out of the atmosphere, then reenter for final descent under parachutes to splashdown.

[Ground testing during the investigation showed] that during the period between dips into the atmosphere, heating rates decreased, and thermal energy accumulated inside the heat shield’s Avcoat material. This led to the accumulation of gases that are part of the expected ablation process. Because the Avcoat did not have “permeability,” internal pressure built up, and led to cracking and uneven shedding of the outer layer.

In other words, instead of ablating off in small layers, the gas build-up caused the Avcoat to break off in large chunks, with the breakage tending to occur at the seams between sections of the heat shield.
» Read more

51 comments

Next two Artemis missions delayed again, with the future of SLS/Orion hanging by a thread

1:22 pm

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”

In a press conference today, NASA officials admitted that their present schedule for the next two Artemis missions will not be possible, and have delayed the next mission (sending four astronauts around the Moon) from the end of 2025 to April 2026, and the next mission (landing astronauts on the Moon) to a year later.

It must be noted that when first proposed by George Bush Jr in 2004, he targeted 2015 for this manned landing. Should the present schedule take place as planned, that landing will now occur more a dozen years late, and almost a quarter century after it was proposed. We could have fought World War II six times over during that time.

Several technical details revealed during the conference:

  • It appears a redesign of Orion’s heat shield will take place, but not until the lunar landing mission. For Artemis-2 (the next flight), engineers have determined they can make the shield work safely by changing the re-entry path. They have also determined that the design itself is still insufficient, and will require redesign before Artemis-3.
  • Though Orion’s life support system will still be flown for the first time on Artemis-2, the first to carry humans, they have been doing extensive ground testing and have resolved a number of issues. They are thus confident that it will be safe to fly with people on its first flight.
  • Though SLS’s two solid-fueled strap-on boosters will be stacked for more than one year when Artemis-2 launches in April 2026, they are confident based on data from Artemis-1 that both will still be safe to use.

The political ramifications that lurked behind everything however are more significant.
» Read more

16 comments

Trump picks billionaire and private astronaut Jared Isaacman to run NASA

10:50 am

Jared Isaacman
Jared Isaacman

Capitalism in space: In a decision that is certain to send shock waves throughout NASA and the established aerospace industry, President-elect Donald Trump today announced that he has chosen billionaire and private astronaut Jared Isaacman to be his nominee for NASA administrator.

Isaacman quickly accepted the nomination.

Besides being a jet pilot with extensive experience in the aerospace industry, Isaacman has also commanded two space missions, financed out of his own pocket. Both missions used SpaceX’s Falcon 9 rocket and Resilience capsule. Both also pointedly avoided any involvement with NASA, spending several days in free Earth orbit instead of docking with ISS. The second mission achieved several major engineering milestones, testing the first privately built spacesuit during a spacewalk while also flying farthest from Earth since the 1970s Apollo missions.

These flights were part of Isaacman’s own long term space program, dubbed Polaris, with two more missions already in planning stages. The first would be another Dragon orbital mission in which Isaacman had tried to get NASA to shape as a Hubble repair mission. NASA declined. The second is intended as a manned mission around the Moon using SpaceX’s Starship.

That program will now likely get folded into NASA’s Artemis program, which we can all expect Isaacman to force major changes. For one thing, this is another blow to the future of SLS and Orion. As a very successful businessman Isaacman will look with great skepticism at this boondoggle.

For another, Isaacman’s markedly different experiences working with SpaceX versus NASA will likely encourage major bureaucratic changes at the space agency. It is almost certain that Isaacman’s manned flights avoided ISS in order to avoid its Byzantine red tape, that would have likely also blocked use of SpaceX’s spacesuit on a private spacewalk. NASA’s decision to reject Isaacman’s proposal to do a simple but very necessary Hubble repair mission will also likely influence his management of the agency. Isaacman is going to force NASA to depend on the private sector more. He is also likely to reduce the agency’s risk adverse mentality that while often reasonable is many times very counter-productive.

Unlike many of Trump’s other radical nominees, I would be very surprised if Isaacman is not confirmed quickly and with little opposition.

Whether Isaacman will still fly his two remaining private Polaris manned missions is at this moment unknown. Practically it would make sense to cancel them, since he will have much bigger fish to fry at NASA. Emotionally and politically however it would be truly spectacular to have NASA’s administrator fly in space, on a mission using no taxpayer funds. That more than anything would demonstrate the ability of freedom and private enterprise to get things done.

32 comments

NASA once again gambling on the lives of its astronauts for political reasons

10:07 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”

NASA this week began the stacking one of the two strap-on solid-fueled boosters that will help power SLS on the Artemis-3 mission, still officially scheduled for September 2025 and aiming to send four astronauts around the Moon.

A NASA spokesperson told Ars it should take around four months to fully stack the SLS rocket for Artemis II. First, teams will stack the two solid-fueled boosters piece by piece, then place the core stage in between the boosters. Then, technicians will install a cone-shaped adapter on top of the core stage and finally hoist the interim cryogenic propulsion stage, or upper stage, to complete the assembly.

At that point the rocket will be ready for the integration of the manned Orion capsule on top.

The article at the link sees this stacking as a good sign that NASA’s has solved the Orion capsule’s heat shield issue that occurred during the unmanned return from the Moon on the second Artemis mission. The image to the right shows that heat shield afterward, with large chunks missing. Though it landed safely, the damage was much much worse than expected. At the moment NASA officials have said it has found the root cause, but those officials also refuse to say what that root cause is, nor how the agency or Orion’s contractor Lockheed Martin has fixed it.
» Read more

19 comments

The dim future of SLS indicated at space business symposium

9:37 am

At a symposium in DC yesterday, a panel of past managers — all of whom had been involved in previous government transitions at NASA — attempted to predict what the consequences will be for NASA with the new Trump administration.

Most of the opinions were pure guesses, some better than others. The real moment of truth came when the entire panel was asked to predict the future of SLS and Orion. The question was put forth by one of the panelists, Lori Garver, who had been NASA’s deputy administrator during the Obama administration, and seemed to have the best understanding of how much the arrival of Trump will likely shake things up significantly.

At one point in the discussion, she asked the panel if they thought the Space Launch System and Orion programs would continue in the next administration. None of the panelists raised their hands. [emphasis mine]

Several of these panelists were big supporters of SLS. Their lack of confidence in its future tells us that SLS and Orion no longer have strong political backing in Washington. Both stand on thin ice.

I predict both will be shut down within the next year, before the next Artemis flight, the first to be manned, to be replaced with a entirely different manned space exploratory program to the Moon and Mars. The decision will be a smart one, but tragically late in coming. SLS should have been dumped years ago. If it had, the U.S. effort to return to the Moon would have been better off, moving forward with a better plan years earlier. Instead, this late decision will once again delay any manned lunar missions for years more.

The change however will be good in the long run, because I expect the new program will be better designed, more efficient, cost less, and be able to do what SLS promised but could never deliver. And it will be based on what private enterprise can accomplish, not a government designed behemoth designed mostly as pork.

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GAO: Next SLS Artemis launches will almost certainly be delayed

10:52 am

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

According to a new Government Accountability Office (GAO) report released yesterday, NASA’S continuing delays and technical problems building the various ground systems required for the next few Artemis launches will almost certainly cause those launches to be delayed.

The schedule at present is as follows:

  • September 2025: Artemis-2 will be the program’s first manned mission, taking four astranauts around the Moon.
  • September 2026: Artemis-3 will complete the first manned lunar landing.
  • September 2028: Artemis-4 will send four astronauts to the Lunar Gateway station in orbit around the Moon, and then complete the second manned lunar landing.

The GAO report notes at length that modifications to the mobile launch platform SLS will use on the first two missions is taking longer than planned. It also notes that the problems completing the second mobile launcher continue, with the budget growing from $383 million to $1.1 billion, and the work years behind schedule with no certainty it will be completed in time for the 2028 mission. These issues are the same ones noted by NASA’s inspector general in August 2024.

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

This report focused exclusively on the scheduling delays for the ground systems that will be used by SLS for each launch. It did not address the serious questions that remain concerning the serious heat shield damage experienced by the Orion capsule when it returned to Earth on its first unmanned mission in late 2022. NASA has been studying that problem now for two years, and as yet has not revealed a solution.

I continue to predict that the first manned landing, now scheduled for 2026, will not occur before 2030, six years behind the schedule first proposed by President Trump but actually fifteen years behind the schedule initially proposed by President George Bush Jr in 2004. All in all, it will take NASA almost a third of a century to put American astronauts back on the Moon, assuming the landing occurs in 2030 as I now predict. Compare that with the development time of SpaceX’s Starship/Superheavy. Proposed in 2017, it is already flying, and will almost certainly complete its first private manned lunar mission and its first test missions to Mars by 2027. The contrast is striking.

More and more the entire part of Artemis run by NASA is proving to be the failed disaster I predicted it would be in 2011. No wonder former New York mayor Michael Bloomberg wrote an op-ed yesterday calling for its cancellation. Like most politicians, reality is finally percolating into his thick skull, though several decades late.

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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

20 comments

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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