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J. Craig McArthurAres I Upper Stage Deputy ManagerJuly 23, 2008
Ares I Crew Launch Vehicle Ares I Crew Launch Vehicle
www.nasa.gov
Upper Stage Element OverviewUpper Stage Element Overview
https://ntrs.nasa.gov/search.jsp?R=20090002561 2020-04-13T04:18:47+00:00Z
What is NASA’s Mission?What is NASA’s Mission?
♦ Safely fly the Space Shuttle until 2010♦ Complete the International Space Station♦ Develop a balanced program of science, exploration, and aeronautics
♦ Safely fly the Space Shuttle until 2010♦ Complete the International Space Station♦ Develop a balanced program of science, exploration, and aeronauticsp p g , p ,♦ Develop and fly the Orion Crew Exploration Vehicle (CEV)♦ Return to the Moon no later than 2020♦ Promote international and commercial participation in exploration
p p g , p ,♦ Develop and fly the Orion Crew Exploration Vehicle (CEV)♦ Return to the Moon no later than 2020♦ Promote international and commercial participation in exploration♦ Promote international and commercial participation in exploration♦ Promote international and commercial participation in exploration
“The next steps in returning to the Moon and moving onward to Mars, the near-Earth asteroids, and beyond, are crucial in deciding the course of future space exploration. We must understand that these steps are incremental, cumulative, and incredibly powerful in their ultimate effect.”
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– NASA Administrator Michael Griffin October 24, 2006
NASA’s Exploration RoadmapWhat is our time line?
NASA’s Exploration RoadmapWhat is our time line?
06060505 0707 0808 0909 1010 1111 1212 1313 1414 1515 1616 1717 1818 1919 2020 2121 2222 2323 2424 252506060505 0707 0808 0909 1010 1111 1212 1313 1414 1515 1616 1717 1818 1919 2020 2121 2222 2323 2424 25…25…
Lunar Robotic Lunar Robotic MissionsMissions
Lunar Outpost BuildupLunar Outpost Buildup
Initial Capability Orion (CEV)Initial Capability Orion (CEV)MarsMars
ExpeditionExpedition~2030~2030
MissionsMissions
Science Robotics MissionsScience Robotics Missions
Research and Technology Development on ISSResearch and Technology Development on ISS
SSP TransitionSSP Transition
Space Shuttle OperationsSpace Shuttle Operations
Commercial Crew/Cargo for ISSCommercial Crew/Cargo for ISS
Ares I and Orion DevelopmentAres I and Orion Development
Operations Capability DevelopmentOperations Capability Development(EVA, Ground Operations, Mission Operations)(EVA, Ground Operations, Mission Operations)
Orion and Ares I Production and OperationOrion and Ares I Production and OperationAres IAres I--XX
Altair DevelopmentAltair Development
Orion and Ares I Production and OperationOrion and Ares I Production and OperationAres IAres I XXTest FlightTest FlightApril 2009April 2009
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011608011608
Ares V & Earth Departure StageAres V & Earth Departure Stage
Surface Systems DevelopmentSurface Systems Development
Building on a Foundation of Proven Technologies– Launch Vehicle Comparisons –
Building on a Foundation of Proven Technologies– Launch Vehicle Comparisons –122 m
(400 ft)
CrewCrew
LunarLunarL dL d
AltairAltair
) 91 m(300 ft)
Earth DepartureStage (EDS) (1 J–2X)234,488 kg (517k lbm)LOX/LH2
LanderLanderOrionOrion
S-IVB(1 J–2 engine)108,862 kg(240k lb )
Upper Stage(1 J–2X)e
Hei
ght,
m (f
t (300 ft)
Core Stage(5 RS–68 Engines)
55--Segment Segment R blR bl
(240k lbm)LOX/LH2
S-II(5 J–2 engines)453,592 kg (1M lbm)
( J )138,350 kg(302k lbm)LOX/LH2
Ove
rall
Vehi
cle 61 m
(200 ft)
(5 RS 68 Engines)1,435,541 kg(3.2M lbm)LOX/LH2
Reusable Reusable Solid Rocket Solid Rocket Booster Booster (RSRB)(RSRB)
Two 5Two 5--SegmentSegmentRSRBsRSRBs
(1M lbm)LOX/LH2
S-IC(5 F–1)1,769,010 kg (3.9M lbm)
O / 1
O
30 m(100 ft)
Space ShuttleSpace Shuttle Ares IAres I Ares VAres V Saturn VSaturn V
LOX/RP-1
Height: 110.9 m (364 ft)Height: 109.7 m (360 ft) G Lift ff M
Height: 99.1 m (325 ft)Height: 56.1 m (184.2 ft)
0
4National Aeronautics and Space AdministrationDAC 2 TR 5
Gross Liftoff Mass:2,948,350 kg (6.5M lbm)
45 MT (99k lbm) to TLI119 MT (262k lbm) to LEO
Gross Liftoff Mass: 3,374,910 kg (7.4M lbm)
63.6 MT (140.2k lbm) to TLI (with Ares I)55.9 MT (123k lbm) to Direct TLI
~143.4 MT (316k lbm) to LEO
Gross Liftoff Mass: 907,185 kg (2.0M lbm)
25.6 MT (56.5k lbm) to LEO
Gross Liftoff Mass: 2,041,166 kg (4.5M lbm)
25 MT (55k lbm)to Low Earth Orbit (LEO)
Ares I Upper StageAres I Upper Stage
AIAI--Li Orthogrid Tank StructureLi Orthogrid Tank Structure
Instrument Unit Instrument Unit (Modern Electronics)(Modern Electronics)
LOX TankLOX Tank
LHLH22 TankTank
Helium Helium Pressurization Pressurization
B lB lFeed SystemsFeed Systems
Common Common BulkheadBulkhead
BottlesBottles
Ullage Settling Ullage Settling MotorsMotors
BulkheadBulkhead Roll Roll Control Control SystemSystemPropellant Load: Propellant Load: 138k kg138k kg
Total Mass:Total Mass: 156 K kg156 K kgDry Mass: 17 5 k kg (Dry Mass: 17 5 k kg (38 6 k lbm)38 6 k lbm)
Composite InterstageComposite Interstage
Thrust Vector Control Thrust Vector Control
Dry Mass: 17.5 k kg (Dry Mass: 17.5 k kg (38.6 k lbm)38.6 k lbm)Dry Mass (Interstage): 4075 kg (Dry Mass (Interstage): 4075 kg (8,984 lbm)8,984 lbm)Length: 25.6 m (Length: 25.6 m (84 ft)84 ft)Diameter: 5.5 m (Diameter: 5.5 m (18 ft)18 ft)LOX Tank Pressure: 344 7 k Pascal (LOX Tank Pressure: 344 7 k Pascal (50 psig)50 psig)
5National Aeronautics and Space AdministrationDAC 2 TR 5
LOX Tank Pressure: 344.7 k Pascal (LOX Tank Pressure: 344.7 k Pascal (50 psig)50 psig)LHLH22 Tank Pressure: 289.6 k Pascal (Tank Pressure: 289.6 k Pascal (42 psig)42 psig)
Upper Stage Primary Products
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Ares I Upper Stage Development ApproachAres I Upper Stage Development Approach
Ames Research Center (ARC)
Glenn Research Center (GRC)• TVC• Electrical Power System• Developmental Flight Instrumentation• Hazardous Gas Detection( )
• Avionics & Software Support
LaRC
ARC
GRC
Langley Research Center (LaRC)
St t l D i S t
SSC
MSFC
• Structural Design Support
• Manufacturing Support
Marshall Space Flight Center (MSFC)
JSC
KSC
Johnson Space Center (JSC)
• Test Support at White Sands
Stennis Space Center (SSC)
• Test Planning and Support
(MSFC)
• US Mgt, Design, and Integration
• US Logistics and Operations Lead
Kennedy Space Center (KSC)
MAF
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Support y p ( )
• Ground Umbilicals Development
• Propellant Systems Development @ MPTA Test Site
• Logistics and Operations Support
Michoud Assembly Facility (MAF)
• Facility Services and Planning Support to ILS and Manufacturing & Assembly IPTs
What progress have we made?What progress have we made?
♦ US Programmatic Milestones• Completed US System Requirements
Review and System Definition
♦ US Programmatic Milestones• Completed US System Requirements
Review and System DefinitionReview and System Definition Review, and currently in the midst of Preliminary Design Review
• Contracts awarded for building the upper stage and instrument unit
• Request for Proposal released for
Review and System Definition Review, and currently in the midst of Preliminary Design Review
• Contracts awarded for building the upper stage and instrument unit
• Request for Proposal released for• Request for Proposal released for Manufacturing Support and Facility Operations Contract (MSFOC) at Michoud Assembly Facility
• Request for Proposal released for Manufacturing Support and Facility Operations Contract (MSFOC) at Michoud Assembly Facility
♦♦ US Technical AccomplishmentsUS Technical Accomplishments•• Robotic Weld Tool now in operation Robotic Weld Tool now in operation
at MSFCat MSFC•• US TVC TestingUS TVC Testing•• US Structural Test PanelsUS Structural Test Panels•• Avionics Computer TestAvionics Computer Test•• First foam spray for cryogenic systemsFirst foam spray for cryogenic systems
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For more information go towww.nasa.gov/ares
•• First Heavy Weight Motor Test and first Ullage Settling First Heavy Weight Motor Test and first Ullage Settling Motor Igniter HotMotor Igniter Hot--FireFire
•• AlAl--Li 2014 dome qualification articleLi 2014 dome qualification article
Upper Stage Subsystem HighlightsUpper Stage Subsystem Highlights♦ Small Solids
• Separation analysis and trade study• Heavy weight motor test• Propellant tailoring and testing• PDR Kickoff
♦ Small Solids• Separation analysis and trade study• Heavy weight motor test• Propellant tailoring and testing• PDR Kickoff SD01 Panel Test• PDR Kickoff
♦ Structures and Thermal• Final Layout Out Reviews• Panel test analysis
♦ Main Propulsion System
• PDR Kickoff
♦ Structures and Thermal• Final Layout Out Reviews• Panel test analysis
♦ Main Propulsion System♦ a opu s o Syste• Terminal drain analysis• Ullage collapse analysis• Bench testing of Saturn Components• Cryo regulator testing
♦ a opu s o Syste• Terminal drain analysis• Ullage collapse analysis• Bench testing of Saturn Components• Cryo regulator testing
TVC Breadboard 1-axis Test Rig
♦ Reaction Control System• Producibility upgrades (DFMA Thruster)• Water Hammer Testing in the CDA
♦ Thrust Vector Control SystemH d li B db d T t
♦ Reaction Control System• Producibility upgrades (DFMA Thruster)• Water Hammer Testing in the CDA
♦ Thrust Vector Control SystemH d li B db d T t
g
• Hydraulic Breadboard Test • PDR Kickoff
♦ Avionics and Software• Boeing Integration• Specification Development
• Hydraulic Breadboard Test • PDR Kickoff
♦ Avionics and Software• Boeing Integration• Specification Development
Test Stand Adapter for Small Solids USM
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• Specification Development• Software Reviews• Industry Day with Supply Chain
• Specification Development• Software Reviews• Industry Day with Supply Chain
Small Solids USM Heavy Wall Motor test
Structural TestingStructural TestingP1P1P1
V
M
Instrument Unit Simulator
Test Fixture
V
M
Instrument Unit Simulator
Test Fixture
V
M
Instrument Unit Simulator
Test FixtureFixture
P
V
M
Fwd Dome / LH2 / IU Simulator
Fixture
P
V
M
Fwd Dome / LH2 / IU Simulator
FixtureFixture
P
V
M
P
V
M
Fwd Dome / LH2 / IU Simulatorz
Constrains panel in rr, rθ
PA
z
Constrains panel in rr, rθ
PA
z
Constrains panel in rr, rθ
PA
z
Constrains panel in rr, rθ
PA
LH2 Tank STA
PLH2
LH2 Tank STALH2 Tank STA
PLH2PLH2Flight-Like LOX Barrel
Flight-Like LH2 Barrel
Aft Dome/Aft Skirt/Interstage
Simulator
Simulator
~38 ft
~21 ft
Common Bulkhead STA
Fill & Drain Port
Flight-Like LOX Barrel
Flight-Like LH2 Barrel
Aft Dome/Aft Skirt/Interstage
Simulator
Simulator
~38 ft
~21 ft
Common Bulkhead STA
Fill & Drain Port
Flight-Like LOX Barrel
Flight-Like LH2 Barrel
Aft Dome/Aft Skirt/Interstage
Simulator
Simulator
~38 ft
~21 ft
Common Bulkhead STA
Fill & Drain Port
θ
z
Con
stra
ins
pane
l in θ,
rr, r
z
Con
stra
ins
pane
l in θ,
rr, r
z
Constrains panel in z, rr, rθ
B
A
B
z
r
A - A
60 in
58 in
θ
z
Con
stra
ins
pane
l in θ,
rr, r
z
Con
stra
ins
pane
l in θ,
rr, r
z
Constrains panel in z, rr, rθ
B
A
B
z
r
A - A
60 in
58 in
θ
z
Con
stra
ins
pane
l in θ,
rr, r
z
Con
stra
ins
pane
l in θ,
rr, r
z
Constrains panel in z, rr, rθ
B
A
B
z
r
A - A
60 in
58 in
θ
z
Con
stra
ins
pane
l in θ,
rr, r
z
Con
stra
ins
pane
l in θ,
rr, r
z
Constrains panel in z, rr, rθ
B
A
B
z
r
A - A
60 in
58 in
Common Bulkhead
~80 ftP2
PLOX
Common Bulkhead
~80 ftP2
Common Bulkhead
~80 ftP2
PLOXPLOX
SD01- AL-Li Small Panel SD02- AL-Li Large Panel
SD03- Common Bulkhead Dev Test
SD06-SD07-SD08 Composite Panel Test
FixtureFixtureFixtureFixture
θr
B - Bθ
r
B - Bθ
rθ
r
B - Bθ
r
B - Bθ
r
B - Bθ
rθ
r
B - B
Aft Skirt/Interstage Simulator
LOX Tank STA
Flight-Like Thrust Structure
T Fi
P3 Aft Skirt/Interstage Simulator
LOX Tank STA
Flight-Like Thrust Structure
T Fi
P3 Aft Skirt/Interstage Simulator
LOX Tank STA
Flight-Like Thrust Structure
T Fi
P3
Paxial
Test Fixture
Aft Skirt STA
LOX Barrel Simulator
V
M
TLN2
Paxial
Test Fixture
Aft Skirt STA
LOX Barrel Simulator
V
M
TLN2TLN2
P
V
MTest Fixture
P
V
MTest Fixture
Fixture
ff tP
LOX Tank Simulator/STE
FixtureFixture
ff tP ff tP
LOX Tank Simulator/STE
SQ02A- Core US
Test Fixture
P4
Test Fixture
P4
Test Fixture
P4
Aft Skirt STA
Interstage STA
Frustrum Simulator
THeat
Discrete Loading for RCS and BSM loads (Locations TBD)
~40 ft
Aft Skirt STA
Interstage STA
Frustrum Simulator
THeatTHeat
Discrete Loading for RCS and BSM loads (Locations TBD)
~40 ft
LH2 Tank Simulator with flight-like y-ring
IU STA
Spacecraft Adapter simulator(composite of same construction as flight SA)
Avionics Panel load points (locations TBD)
~15 ft
Ttop(~ 230 ¼F)
Tbottom(~ -423 ¼F)
LH2 Tank Simulator with flight-like y-ring
IU STA
Spacecraft Adapter simulator(composite of same construction as flight SA)
Avionics Panel load points (locations TBD)
~15 ft
Ttop(~ 230 ¼F)
Tbottom(~ -423 ¼F)
Flight-Like LOX Barrel
Thrust Structure STA
~35 ft
LOX Tank Aft Dome STA
PoffsetP
Aft DomeT
PActuator T
Flight-Like LOX Barrel
Thrust Structure STA
~35 ft
LOX Tank Aft Dome STA
PPoffsetPoffsetP
Aft DomeTAft DomeT
PActuator T
10National Aeronautics and Space Administration10
SQ02A Core US Qualification & Life Test
Test Fixture
Frustrum Simulator
Test Fixture
Frustrum Simulator
Test FixtureTest Fixture
SD05, SQ07- LOX Tank Aft Dome with Thrust Structure and Aft Skirt
SQ05, SQ06- Interstage Qualification Test
SQ01- IU Qualification Test
PThrust
Actuator
VGimbal
TThrust Cone
PThrust
Actuator
VGimbal
TThrust Cone
Common Bulkhead Processing
11National Aeronautics and Space Administration
Stage Installation at Stennis Space Center
12National Aeronautics and Space Administration
Boeing Producibility TeamBoeing has been selected as USPC
and the IUACProducibility and Design SupportManufacturingManufacturingOperations Sustaining Engineering
Program Manager – Jim Chiltong gIUAC Manager – Dwight Potter
Team is engaged with the NASA Design Team (NDT)
Manufacturing Value Stream Mapping
Producibility SummitTooling Design SupportTooling Design SupportSchedule DevelopmentComponent Cost Updates Test Article Planning Support
13National Aeronautics and Space Administration
Special Studies
Upper Stage Low Cost StrategyUpper Stage Low Cost Strategy
♦ Upper Stage acquisition strategy maximizes price competition
• Minimal proprietary items
♦ Upper Stage acquisition strategy maximizes price competition
• Minimal proprietary itemsy− NASA in-house design with commercial production
• Large supplier base for components− Boeing approach maintains competition from large supplier
base
• Procure Sustaining Engineering and Operations using IDIQ (buy it by the yard)
y− NASA in-house design with commercial production
• Large supplier base for components− Boeing approach maintains competition from large supplier
base
• Procure Sustaining Engineering and Operations using IDIQ (buy it by the yard)g ( y y y )
♦ Total cost of ownership is addressed early in the design cycle
• Safety emphasized in all phases of design and production
g ( y y y )
♦ Total cost of ownership is addressed early in the design cycle
• Safety emphasized in all phases of design and productionp
• Value Stream Mapping of the entire manufacturing, test, and operations flow
− Design Production and Ops flows along with the Upper Stage product
• Design for Production and Operations− Boeing provides "Producibility" input to the NASA Design
p• Value Stream Mapping of the entire manufacturing,
test, and operations flow− Design Production and Ops flows along with the Upper Stage
product
• Design for Production and Operations− Boeing provides "Producibility" input to the NASA Design g p y p g
Team
• Optimized Manufacturing and Production Plans− Design for low cost manufacturing to minimize "monuments"
in the production flow
• Operation Concept Analysis - to minimize "monuments" in the operations flow
g p y p gTeam
• Optimized Manufacturing and Production Plans− Design for low cost manufacturing to minimize "monuments"
in the production flow
• Operation Concept Analysis - to minimize "monuments" in the operations flow
14National Aeronautics and Space Administration
p− Depots (no depot at KSC or SSC)− Support equipment (flexible support equipment)− Workforce (no standing army)
p− Depots (no depot at KSC or SSC)− Support equipment (flexible support equipment)− Workforce (no standing army)
Ares I and V Production at Michoud Assembly Facility (MAF)
Ares I and V Production at Michoud Assembly Facility (MAF)
CoreCore US
EDS
NCAMNCAM
Shared
Orion
Shared
15National Aeronautics and Space Administration
Merged Manufacturing FlowMerged Manufacturing FlowCommon Test Cell♦ Manufacturing Value Stream Map
125.00 J2X 5.50
G1 G2
♦ Manufacturing Value Stream Map♦ Vertical Tack and Weld♦ Horizontal TPS Application
♦ Producability SummitM f t i Pl
MetricsNASA Baseline 420 days
153.5 TC TC34 120 9.5
177.63 ASB AS32.63 145 35
G1 G2 CTC
♦ Manufacturing Plan♦ Manufacturing Floor Plan at Michoud♦ Tooling Design and Fabrication
Boeing Contract 347 daysMerged VSM 320 daysWith learning <300 days
225.75 IUB IU IUAC IU 110 1418.75 24 60 123 13
217 HB1 G1217 HB2 VTWB217 HB3 11.00 213 FD
12 31
LH2 Tank
246 AD39.5
G1 G2 G2 G3 G1 G2 G3 G1 G2 G3 G4 G5G2 G1 VTWA VTWA VTWB VTWA HT HT HT INT INT INT INT INT
232.75 LTB LTB 5 201.75 7.75 12.00 182 6 11.5 45.5 23 96 7 11 7.5 33.5 3719.00 7.00
LOX Tank Critical Path
G1 G3312.50 OFD CB CB
12.75 32 66G2
Final Assembly & Integration
16National Aeronautics and Space Administration16
288.50 HAD CB12.75 8
84 TN 84 IS13 46.5
Common BulkheadVertical Tank Assembly
Boeing, working with NASA, Reduced Assembly Flow Over 100 days
Manufacturing & Assembly Weld ToolsManufacturing & Assembly Weld Tools
MSFC Bldg 4755Robotic Weld Tool (RWT) gore-gore, dome-y ring, dome-fittingSelf-Reacting Friction Stir Welding (FSW)
17National Aeronautics and Space Administration
Vertical Weld Tool (VWT)Barrel-Barrel, Conventional FSW
Vertical Circumferential Weld Tool Concept
Conclusion
♦ Building on the heritage of the Apollo and Space Shuttle Programs, the Ares I Upper Stage team is utilizing extensive lessons learned to place NASA and the United pStates into another great era of space exploration
• Ares I team must build beyond its current capability to ferry astronauts and cargo to Low Earth Orbit
• To reach for Mars and beyond, the team must first reach for the moon
• We are using the best of NASA to design the stage, and the best of industry to build the stage
♦ NASA and Boeing Upper Stage teams are♦ NASA and Boeing Upper Stage teams are now integrated, working together, and making good progress
• Designing and building the Ares I Upper to minimize:− Cost risksCost risks− Technical risks− Schedule risks
“This Nation has tossed its cap over the wall of
18National Aeronautics and Space Administration
space, and we have no choice but to follow it.”
-- President John F. Kennedy, 1962