J. Craig McArthur Ares I Upper Stage Deputy Manager July 23, 2008 · 2013-04-10 · Ares I Upper...

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.”

2National Aeronautics and Space Administration

– 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


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


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


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


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


• 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


Test Fixture

V

M


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


PA

z


PA

z


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



Simulator

Simulator

~38 ft

~21 ft

Common Bulkhead STA

Fill & Drain Port




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


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


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


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


T Fi

P3 Aft Skirt/Interstage Simulator

LOX Tank STA


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)


Thrust Structure STA

~35 ft

LOX Tank Aft Dome STA

PoffsetP

Aft DomeT

PActuator T


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


Stage Installation at Stennis Space Center


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


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


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


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)


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


space, and we have no choice but to follow it.”

-- President John F. Kennedy, 1962

J. Craig McArthur Ares I Upper Stage Deputy Manager July 23, 2008 · 2013-04-10 · Ares I Upper...

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Transcript of J. Craig McArthur Ares I Upper Stage Deputy Manager July 23, 2008 · 2013-04-10 · Ares I Upper...