Tag: SLS

Experts: NASA’s SLS Mars proposals bunk

9:48 am

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

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

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

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

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

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First SLS launch will carry 13 cubesats

10:42 pm

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

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

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NASA ships a capsule

9:10 am

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

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

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

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

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Orion: construction in slow motion

9:57 am

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

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

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

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

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

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

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

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

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SLS still has no mission

9:04 pm

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

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

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

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NASA contracts Aeroject Rocketdyne to build shuttle engines for SLS

5:27 pm

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

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

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

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NASA delays first Orion manned flight two more years

4:02 pm

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

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

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

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

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

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Cubesats to the Moon!

5:05 pm

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

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

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

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

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

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Orion might not be ready for 2018 test flight

8:42 am

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

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

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

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

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

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

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

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

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NASA considers offering SLS for commercial payloads

9:13 am

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

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

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

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Russia considers building heavy-lift rocket like SLS

10:05 am

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

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

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

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

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

10:01 am

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

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

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

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

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

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Incorrectly built SLS welding machine to be rebuilt

9:16 am

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

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

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

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

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

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

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NASA to use giant SLS rocket to launch cubesats

9:50 am

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

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

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

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Further SLS delays loom

9:32 pm

A report by NASA’s inspector general finds that the planned first launch of the SLS rocket in November 2018 is threatened with delay because the ground facilities at Kennedy might not be ready.

In a report released Wednesday, NASA’s Office of Inspector General warned that Ground Systems Development and Operations, or GSDO, may be hard-pressed to have Kennedy Space Center’s launch facilities ready on time. Ground systems are a critical piece of the SLS-Orion infrastructure. All three elements are tightly integrated, with ground systems requiring significant input from the rocket and capsule designs. “GSDO cannot finalize and complete its requirements without substantial input for the other two programs,” said Jim Morrison, the assistant inspector general for audits. “And NASA is still finalizing the requirements for those programs.”

Gee, I guess SLS isn’t getting enough money, as its budget is only about $3 billion per year (about six times what the commercial space program gets per year, a program that has already created two freighter systems for ISS and is now creating two manned ferry systems for ISS). Why don’t we give them more, so that even more won’t be done with the money we spend?

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Europe’s last ATV leaves ISS

9:44 am

Europe’s last ATV cargo freighter for ISS left the station and burned up over the Pacific Ocean this past weekend.

Because of a technical problem on the ATV, a camera designed to record what happened inside the freighter as it burned up during re-entry was removed prior to undocking so that it could be used instead during a later re-entry.

Meanwhile, instead of supplying ISS with cargo, Europe has decided to meet its contribution to ISS by building the service module for NASA’s Orion/SLS program, which has no plans to ever go to ISS. Note, however, that Europe has also not committed to building more than two service modules, so how Orion/SLS will go beyond Earth orbit after these two modules have been launched remains a mystery.

If you are scratching your head at all this, you are not alone. To me, this one decision alone illustrates quite neatly the utter stupidity of big government-run programs.

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NASA safety panel questions safety of SLS

10:47 am

NASA’s safety panel has issued a report questioning the safety of the early launches of the Space Launch System (SLS), partly due to the very low launch rate and the lack of any planned unmanned test flights for the rocket’s upper stage engine.

“The ASAP and the Agency remain concerned about risks introduced in the currently scheduled frequency of SLS/Orion launches, ” according to ASAP’s 2014 Annual Report. “The plan indicates a launch about every 2 to 4 years. This would challenge ground crew competency. The skills, procedures, and knowledge of conducting the launch, mission, and recovery are perish-able. The ASAP believes that an extended interval requires the relearning of many lessons and skills, in contrast to Apollo and Shuttle, which had a relatively steady cadence.”

No space project can accomplish anything with launch rate this slow. Not only does this increase the risk that inexperience will cause errors, the long time gaps make it difficult for the project to get anything done.

And then there is NASA’s idea that it can put humans on this rocket without any previous launch testing of the rocket’s upper stage or the capsule’s life support systems. Why should NASA’s rocket get a pass on this kind of testing when the agency is demanding that the private companies do it?

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Cruz and Rubio to chair important space and science subcommittees

3:40 pm

We are about to find out how conservative and pro-private enterprise senators Ted Cruz (R-Texas) and Marco Rubio (R-Florida) really are. Both have been assigned as chairmen of important subcommittees managing NASA and NOAA.

Cruz will chair the subcommittee on Space, Science, and Competitiveness, which handles NASA, while Rubio will chair the subcommittee that handles NOAA.

For Cruz especially this position will challenge him to prove his tea party credentials. If he is in favor of private space as much as he claims, we will see him work to trim SLS, a pork project with no hope of achieving anything in space, and favor the commercial space effort, even though SLS brings much more pork into his state.

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NASA builds a $349 million test stand it knows it will never need

11:58 pm

SLS marches on! Though Obama cancelled the Constellation rocket program in 2010, NASA continued to build a $349 million engine test stand for that rocket, finishing the tower in June 2014.

The test stand was also significantly over budget. It now sits useless, since the SLS rocket will use a different untested engine in its upper stage during its first manned flight.

It is every important to underline the chronology here. The rocket was cancelled in 2010. Construction on the test stand continued however for four more years, partly because of decisions by NASA management and partly because of mandates forced on them by Congress.

Stories like this illustrate why I think the political clout of SLS is weak. The program is too expensive, is riddled with waste, and it can’t accomplish anything anyway, making it a perfect target for both muckraking journalists and elected officials who want to make a name for themselves saving the taxpayer’s money. And both have a perfect inexpensive and successful alternative to turn to: private space.

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Orion launch on Thursday given go-ahead

1:30 pm

The Thursday test launch of an Orion capsule has been given the go-ahead.

Many of the news reports this week about this test flight have referred to Orion as “the spacecraft that will take humans to Mars.” I must note again that this is hogwash. No humans will ever go to Mars using Orion. It is too small and does not have the capacity to keep humans healthy and alive for the year-plus-long flight time necessary to get to and from Mars.

The most Orion can ever be is the ascent and descent module for a much larger interplanetary space vessel, used just for getting humans up and down from the surface of the Earth. The spacecraft that will really take people to Mars will have to be something more akin to Mir or ISS, a large assembly of modules put together in low Earth orbit.

One other tidbit everyone should know about tomorrow’s test flight: Though it is being touted as a test of Orion’s heat shield, the company that makes this heat shield has already abandoned this design, so the test itself is for a heat shield that will never be launched again on another Orion capsule. In addition, the flight won’t test the rocket to be used, as the SLS rocket isn’t ready. Nor will it test the capsule’s life support systems, which are not on board.

Which immediately raises the question: Why in hell is NASA even bothering with this test flight?

Sadly, I can answer that question. This is all public relations, an effort to lobby for funding. That’s it.

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A scrambled SLS/Orion flight schedule

12:40 am

It ain’t gonna happen: In trying to figure out what to do with SLS/Orion, NASA has admitted that the earliest any crew mission to an asteroid can occur is now 2024.

I could quote from the article, but then I’d have to quote the entire article and comment on the absurdity of practically every sentence. NASA hasn’t the faintest idea what to do with SLS, it isn’t designed to do much of anything, and it doesn’t have the funding to anything even if they knew what they wanted to do with it. Hence, the constant scheduling rearrangements, all designed to push the actual manned flights farther and farther into the future.

The article does point out how NASA is now planning to fly its first crewed mission on SLS/Orion using an untested upper stage, since the rocket costs so much to launch they can’t afford to spend the money on an unmanned test flight beforehand. Meanwhile, they are demanding that SpaceX and Boeing do all kinds of unmanned test flights with their manned capsules at great cost to these companies, before allowing any astronauts on board.

As I’ve said repeatedly, this rocket is never going to fly anyone anywhere. By 2020 several private companies will be sending humans into space regularly at far less cost and with far greater capabilities. Congress will finally realize that they can spread their pork around more effectively by funding these companies instead, and they will cancel this bloated and wasteful program.

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Orion heat shield redesigned before its launch?

9:59 am

Even before Orion’s first flight next month to test its heat shield, engineers are proposing a major change in the shield’s design and manufacture.

The Orion heat shield’s titanium skeleton and carbon fiber skin was fabricated by Lockheed Martin — the craft’s prime contractor — in Colorado. The skeleton was shipped to Textron Defense Systems in Massachusetts for installation of a fiberglass-phenolic honeycomb structure. More than 330,000 individual cells make up the honeycomb, and Textron technicians — using a special dispensing gun — filled the cells by hand with a material called Avcoat. The Avcoat insulation is supposed to ablate away during the Orion spacecraft’s re-entry, protecting the underlying structure from searing temperatures. The Apollo moon capsule used the same type of manually-applied material for its heat shield, and it worked so well Lockheed Martin and NASA decided to dust off the design.

Engineers scaled up the heat shield for the Orion crew capsule, which is about four feet wider at its base than the Apollo command module. “That’s what worked for Apollo, and that’s what we’ll work with for this mission,” Bray said, referring to the EFT-1 launch in December.

But a review of the heat shield on the Orion spacecraft set for launch Dec. 4 revealed the Avcoat was slightly more uneven than expected, according to Jim Bray, crew module director at Lockheed Martin, Orion’s prime contractor.

It also appears that it is too expensive to build the shield by hand, as it was done during Apollo. Instead, they intend to build future heat shields as single blocks assembled not by hand but by machine.

This is another example of why SLS/Orion is an incredible money black hole. What is the point of next month’s test flight of the heat shield if the shield they are testing is not going to be used on future flights?

Meanwhile, the press (apparently ignorant and uninformed about this subject and brainwashed by a NASA Orion press event) is filled with numerous stories claiming that this test flight is NASA’s first step to getting to Mars. What hogwash.

I especially like this quote from the space.com article:

On Dec. 4, NASA officials are expected to launch the Orion spacecraft on its first test flight, putting the capsule through its paces in space before it splashes down in the Pacific Ocean. The goal of the flight is to see how some key Orion systems — like its huge heat shield and parachutes — work before launching humans into deep space sometime in the future. [emphasis mine]

Yet, most of the heat shield test data obtained by this test flight will be worthless and inapplicable to future Orion capsules. In other words, this test flight is, as I said, hogwash, a public relations stunt to sell Orion to Congress and to uneducated reporters. It is also an enormous waste of taxpayer money and the limited resources NASA has.

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Orion ready for launchpad!

9:15 am

Be still my heart! NASA has completed the assembly of the Orion capsule stack, prior to installing it on its rocket on the launchpad.

I remain decidedly unexcited by this upcoming test flight, which will send Orion up to 3,600 miles and then bring it back to Earth at about 20,000 miles per hour to test the spacecraft’s heat shield.

For example, the exaggerations and overstatements in this one short article tell you a great deal about how oversold the SLS/Orion program is.
» Read more

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Launch abort system installed on Orion for December test flight

9:14 am

Engineers have installed a test version of the launch abort system (LAS) for the first test flight of the Orion capsule in December.

The LAS will not be active during the uncrewed EFT-1 mission, but during future missions it will be equipped to act within milliseconds to pull the spacecraft and its crew away from its rocket so that Orion could parachute safely back to Earth.  While the abort motors  are inert and not filled with solid fuel, the LAS will have an active jettison motor so that it can pull itself and the nose fairing away from the spacecraft shortly before Orion goes into orbit. The flight test will provide data on the abort system’s performance during Orion’s trip to space.

Based on what I know of the Orion/SLS launch schedule, I don’t think NASA ever intends to test it during a full launch of the SLS rocket. For one thing, the rocket is too expensive and NASA can’t afford to waste a launch just to test this one component. For another, the rocket’s development is too slow as it is, with the first launch not scheduled until 2018 and the first manned flight not until 2021, at the earliest. If they add a launch test of the abort system, NASA might not fly an SLS manned mission until late in the 2020s.

Meanwhile, NASA is sure insisting that SpaceX do such tests. And they will, since their capsule and rocket is affordable and quick to launch. What does that tell us about the two systems? Which would you buy if you were the paying customer?

Oh wait, you are the paying customer! Too bad you your managers in Congress don’t seem interested in managing your money very wisely.

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Delta 4 Heavy moved to launchpad for Orion flight

10:09 am

In preparation for a December test flight of the first Orion capsule, the Delta 4 Heavy rocket has been positioned on the launchpad.

The unmanned Dec. 4 mission, known as Exploration Flight Test-1 (EFT-1), is designed to test out Orion’s critical crew-safety systems, such as its thermal-protection gear. During the four-hour flight, the Orion capsule will fly 3,600 miles (5,800 kilometers) from Earth, then come speeding back into the planet’s atmosphere at about 20,000 mph (32,190 km/h) before splashing down softly in the Pacific Ocean, NASA officials said.

Forgive me if I remain decidedly unexcited. I still believe SLS to be an enormous waste of resources that would be better spent onother things.

Posted on the road south of Phoenix.

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Washcloth delays SLS engine tests

8:59 am

The testing of an engine for the giant SLS rocket will be delayed because engineers have found the remains of a washcloth in the ducts of the test stand at Stennis Space Center.

The investigation found the fibers belong to a cotton shop rag from a weld shop that had been involved with working on the LOX duct ID surface during manufacture. The roughened surface (of the duct) was where the fibers were observed to be hanging up on.

The investigation team reported that, under microscope inspection, a piece of the run duct stock showed metallic particles loosely adhered to the ID surface and embedded in the ‘machining’ groves. Several were easily dislodged and identified as ID surface material. “A tape sample was pulled from the same stock (after an identical cleaning process) and produced a rather large quantity of particles. This is an unacceptable condition and it was agreed that the entire run duct will need to be replaced or reworked (~30-ft of pipe),” added the investigation notes.

Replacing the duct will cause a several month delay in the test program. Fortunately for NASA, they have some wiggle room (for the moment), since the entire SLS schedule has already slipped a year to 2018.

Nonetheless, do not be surprised if this is only the first of many further delays.

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