“So I’m doing structural test article stuff in parallel with the flight article, and that was a completely acceptable thing to do from a programmatic risk standpoint and offered substantial scheduling advantage to do that.”. “There’s the Universal Stage Adapter which is being managed by the SPIE (Spacecraft Payload Integration and Evolution) organization, that’s the adapter that goes between the Orion vehicle and the EUS, so that’s new and under development. NASA’s Space Launch System, or SLS, is a super-heavy-lift launch vehicle that provides the foundation for human exploration beyond Earth’s orbit. “I took [the STA] off my critical path intentionally,” Wofford explained. The factory had been shut down essentially, it was a new design, it was the first article of a new design, it was new people — it was new everything. Standing up EUS manufacturing, production for first flight. Still, Wofford noted it’s a bigger challenge to fire a cluster of them in a vacuum. “We are continuing to mature the EUS and Block 1B designs towards the next steps in their maturity.”, “There’s a series of gate reviews, design reviews that are at maturity states beyond the CDR that we just completed, so we’ll be marching through those in the months and years to come. If you continue to use this site we will assume that you are happy with it. As of February 2015[update], the SLS Block 1B will provide thrust of 105 t (103 long tons; 116 short tons). (Photo Caption: The B Test Stand at Stennis Space Center; the B-2 position on the right will be modified to perform a Green Run test campaign on the first EUS flight article prior to launch. It will be powered by four RL10-C3 [4] engines burning liquid oxygen and liquid hydrogen to produce a total of 440 kN (99,000 lbf) thrust. Due to the possible cost of EUS (about US$800 million each), NASA invited proposals for alternatives, but in May 2019 rejected Blue Origin's proposal. “We’re inheriting a lot of the facilities, we’re inheriting a lot of the tooling, we’re certainly inheriting trained and experienced personnel,” Wofford noted. This change has necessitated a reex-amination of the flight profile to determine what changes must be made in order ... For the original EM-2 Block 1B … The improved upper stage was originally named the Dual Use Upper Stage (DUUS, pronounced "duce")[10] but was later renamed the Exploration Upper Stage (EUS) due to DUUS sounding like a profanity in Japanese. Boeing has announced that the Exploration Upper Stage (EUS) for Nasa’s Space Launch System (SLS) rocket passed the critical design review (CDR). One of the development tasks is to certify how to weld the different materials together. NASA contracted with The Boeing Company (Boeing) in 2012 to build two SLS Core Stages—that is, the first stage of the rocket consisting of the fuel tanks and supporting infrastructure—and later an Exploration Upper Stage (EUS), a new and more powerful second stage designed to increase the SLS’s upmass capability. “It’ll be how flight software commands the [RL10] engines to start and stop as well as the propellant utilization control as well,” Dan Mitchell, NASA’s Technical Lead for SLS avionics and software engineering, said. During the redesign of the EUS, the interstage element that connects EUS with the SLS Core was also modified. [8][9], NASA will develop the EUS to increase SLS performance beyond Block 1 specifications. The milestone confirms that the EUS’s design meets requirements for future missions in deep space environments and ensures the safety of astronauts. With its unprecedented power and capabilities, SLS is the only rocket that can send Orion, astronauts, and cargo to the Moon on a single mission. (Photo Caption: A composite of NASA and NASA Inspector General Office diagrams showing the different organizational levels inside and outside the SLS Program. “In terms of manufacturing readiness, I’m really pleased with the progress we’re making there. In its Cargo configuration, Block 1B is expected to be able to insert payloads of greater than 40 metric tons on a trans-lunar trajectory. The biggest area besides EUS and the Universal Stage Adapter that’s being worked on is in terms of avionics and software [development] and the vehicle engineering tasks, the analysis tasks like trajectories and loads and environments and performance projections and that sort of thing. The Catch. [It’s] a pretty well-known engineering exercise,” Wofford added. NASA received two responses for the production and evolution of the SLS. As NASA marked the completion of the first SLS core stage, the agency and Boeing are in negotiations for a long-term production contract. “The structural test article will be tested at Marshall, and we are scheduled to wrap up that testing in October of 2023,” Wofford added. The Block 1B vehicle-level CDR will be in June of next year.”, STA and flight article will help verify, certify design for first launch. A structural test article (STA) will be assembled at MAF and tested at the Marshall Space Flight Center (MSFC) in Huntsville, Alabama. (Photo Caption: Updated NASA renders of the Exploration Upper Stage in development by the SLS Program. Learn more here. The Space Launch System (SLS) is the American heavy lift launch vehicle and is part of NASA‘s deep space exploration plans. Launch Vehicle Comparison: Payload to TLI II. The SLS team is producing NASA’s first deep space rocket built for human space travel since the Saturn V. Engineers are making progress toward delivering the first SLS rocket to NASA’s Kennedy Space Center in Florida for its first launch on the Artemis I lunar mission. Sparks also noted that currently, the plan for the EUS Green Run hot-fire test would be to perform a burn of approximately 350 seconds to collect the data needed for design verification objectives and to help certify the stage for its first flight. The flight computers and redundant inertial navigation unit that fly with the Core Stage during Block 1 launches will move up to the EUS for the longer mission; the vehicle flight software will also evolve to support the hours-long mission from the minutes-long Block 1 flights. The new upper stage is an in-house development effort between NASA’s SLS Program and Boeing and is sized to SLS dimensions. SLS CORE STAGE DEVELOPMENT The SLS Block 1 is progressing toward a late 2020 launch. The SLS (Space Launch System) is NASA's planned heavy lift rocket replacing the cancelled Ares-5 concept. Following its Critical Design Review in December, NASA and Boeing are finalizing weld parameters to assemble the structures for the new Exploration Upper Stage. The Exploration Upper Stage (EUS) is being developed as a large second stage for Block 1B of the Space Launch System (SLS), succeeding Block 1's Interim Cryogenic Propulsion Stage. CREDIT NASA — SLS Block 1 and SLS Block 1B. The RL10 is used by different launch providers in their upper stages, with the main hardware difference being the number and length of nozzle extensions. 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Boeing, the prime contractor for NASA’s SLS, announced this week that they have completed a critical design review for the new upper stage of the rocket. [13], By February 2020, the development contract for EUS had been delayed and NASA was planning to use ICPS for the first three launches of SLS. The Block 1 configuration of SLS will have a core stage powered by four RS-25 engines, two Space Shuttle-derived five-segment solid rocket boosters, and an Interim Cryogenic Propulsion Stage (ICPS) upper stage. The two isogrid panels were friction-stir welded together, and then large sections of the weld were cut out for engineering evaluations.). nasa-slspayloads@mail.nasa.gov 1.0 Lunar Vicinity For typical SLS Block 1B missions to cislunar destinations (e.g., Lunar Gateway), the SLS ... details; the ISPE includes all equipment between the SLS EUS and Orion for the crew configuration and all equipment above the SLS EUS for the cargo configuration. On Orion missions, Block 1B has enough performance to “co-manifest” a large secondary payload of approximately 10 metric tons. On 10 February 2021, it was announced the program would no longer … Much of the tooling at Michoud used to assemble Core Stage hardware will also be used in assembly of the EUS. [6][7], The Block 1 configuration of SLS will have a core stage powered by four RS-25 engines, two Space Shuttle-derived five-segment solid rocket boosters, and an Interim Cryogenic Propulsion Stage (ICPS) upper stage. “If I’m not mistaken, there’s like six different joints of different alloys that we’ve got to go qualify,” Sparks noted. You would think that we would select one alloy and go with it.”, “But what we can do is we really can optimize the design by selecting specific alloys that give us specific properties. Note: the SPL shown in Figure 3 is representative of a SPL volume (6U to 27U) mounted … [5] The EUS is expected to first fly on Artemis IV in March 2026. Rocket Lab reveals reusable, medium-lift Neutron rocket. NASAs Space Launch System, or SLS, is an advanced launch vehicle that provides the foundation for human exploration beyond Earths orbit. SLS (Block-1B) EUS (Orion) [NASA] SLS (Block-1B) EUS (Cargo) [NASA] The SLS (Space Launch System) is NASA's planned heavy lift rocket replacing the cancelled Ares-5 concept. NASA is working to land the first woman and the next man on the Moon by 2024. "Hence, it is not in the critical path (for the Moon landing)." The first flight article will then be completed and travel from Michoud to the relatively nearby Stennis Space Center in southern Mississippi for a Green Run test campaign similar to the one that the first Core Stage is going through. “The idea then is we could just plug and play,” Wofford added. The SLS will be designed to carry the Orion Multi-Purpose Crew Vehicle, as well as important cargo, equipment and science experiments to Earth's orbit and destinations beyond. [16], Rocket stage in NASA's Space Launch System, "NASA, Boeing Finalize US$2.8 billion SLS Core Stage Contract", "NASA confirms EUS for SLS Block IB design and EM-2 flight", "MSFC propose Aerojet Rocketdyne supply EUS engines", Proven Engine Packs Big, In-Space Punch for NASA's SLS Rocket. [14], Boeing announced on 21 December 2020 that the Exploration Upper Stage (EUS) of the SLS completed a critical design review (CDR) with NASA. We use cookies to ensure that we give you the best experience on our website. The SLS will be designed to carry the Orion Multi-Purpose Crew Vehicle, as well as important cargo, equipment and science experiments to Earth's orbit and destinations beyond. Some of the early phases of work on the first flight article, such as welding and assembly of structures, will overlap with STA work. When NASA's SLS rocket takes off on its first flight, Artemis I, it will produce a maximum 8.8 million pounds of thrust, exerting more power than any rocket ever. “EUS leverages all of those lessons learned and all of that ground we already paid for with Core Stage.”, (Photo Caption: A weld confidence article of two test interstage panels is lifted out of the Vertical Weld Center at MAF in February. On the SLS Block 1B vehicle, EUS will replace the Interim Cryogenic Propulsion Stage (ICPS), which a close derivative of the upper stage of United Launch Alliance’s (ULA) Delta IV launch vehicle. With its unprecedented power and capabilities, SLS is the only rocket that can send Orion, astronauts and large cargo to the Moon on a single mission. The first flight article will then be completed and travel from Michoud … “We’re going to run Green Run with sea-level RL10s,” Wofford explained. The first flight article will first be barged over to the relatively nearby Stennis Space Center in southern Mississippi for a “Green Run” test campaign similar to the one that NASA and Boeing are currently trying to finish on the first SLS Core Stage in the B-2 Test Stand. That review confirmed the design of the EUS, allowing Boeing to proceed with development of the stage, including hardware fabrication.[15]. Manufacturing, assembly, integration, and testing of the first flight article at MAF is currently forecasting completion near the end of 2023. [4], In 2018, it was decided to optimise EUS for payload to lunar missions, by using smaller tanks. So Core Stage startup manufacturing was understandably difficult.”, “EUS, it’s not brand new,” he added. “The biggest top-level reason for that is we weren’t starting from scratch.”, “With Core Stage, everything was new. NASA’s SLS Program and EUS prime contractor Boeing are preparing to begin construction of the test and flight articles that will be needed to certify and fly the new upper stage’s first launch. But for the most part, what we’re doing here is for performance.”. October 2016, "Advanced Boosters progress towards a solid future for SLS", "NASA's Management of the Gateway Program for Artemis Missions", "NASA Commits to Future Artemis Missions With More SLS Rocket Stages", "SLS prepares for PDR – Evolution eyes Dual-Use Upper Stage", "SLS positioning for ARRM and Europa missions", "Wind Tunnel testing conducted on SLS configurations, including Block 1B", "SLS Exploration Upper Stage passes review", https://en.wikipedia.org/w/index.php?title=Exploration_Upper_Stage&oldid=1008493762, All Wikipedia articles written in American English, Articles containing potentially dated statements from February 2015, All articles containing potentially dated statements, Creative Commons Attribution-ShareAlike License, This page was last edited on 23 February 2021, at 16:05. The flight article structures will be integrated with flight subsystems such as computers and navigation, electrical power, main propulsion system, and its four rocket engines. “We changed the interstage configuration to make it longer to accommodate future evolution of the engine sizes, the RL10 nozzles,” Todd Holloway, the Contracting Officer Representative for NASA’s Block 1B/EUS Development Office, said. SLS will leave low-Earth orbit and send the Orion spacecraft, its astronaut crew and cargo to deep space. The SLS has been proposed as the launch vehicle for the future Large UV Optical Infrared Surveyor ... was proposed to be launched aboard an SLS in the mid-2020s. It has the same 8.4-meter/27.6-foot diameter to the SLS elements it connects, the aft adapter of the EUS, and the forward skirt of the Core Stage. “We start fabrication of our structural test article this June, this summer,” Steven Wofford, manager of NASA’s new Block 1B/Exploration Upper Stage Development Office, said in a February interview. Before welding the STA hardware, the weld schedules are being refined for the different tools, different materials, and different thicknesses used in the structures for the EUS and the interstage element that connects EUS with the SLS Core Stage. EUS is the same 8.4-meter/27.6-foot diameter as the SLS Core Stage, and the hydrogen-oxygen stage uses four Aerojet Rocketdyne RL10 engines. Public renderings of the interstage were recently updated to match the real interstage’s appearance. The design of the stage was refined over the last couple of years to establish a minimum of 10 metric tons of secondary, “co-manifested” payload could be delivered with an Orion spacecraft and crew to the Moon.). A notional secondary payload module is shown in the drawing; the co-manifested payload would ride on top of the EUS below Orion housed in a Universal Stage Adapter being developed by Dynetics and NASA.). “Aerojet Rocketdyne, the contractor, is very experienced in analytically reconciling the sea-level test with the flight engine performance. NASA has previously advertised a co-manifested payload capacity of about ten tons for the SLS Block 1B. The interstage baseline currently only has a coat of primer for corrosion protection and a coat of white paint on the outside; the only thermal protection spray-on foam insulation would be applied at the flanges of the two connection points with the EUS at the top and the Core Stage at the bottom. Once the Core Stage finishes its Green Run test campaign in the B-2 position of the test stand, modifications will be made to test the first flight EUS unit there in 2024. “When you put four of them together, then being able to construct a diffuser that can evacuate that gigantic volume on the gigantic structure at B-2 becomes problematic at best,” he said. Additionally, the SLS will serve as a back up for … “When the C-X becomes the existing product line sometime in the future, then we can just plug and play within our existing outer mold line with that new engine.”. Most recently, test panels for an interstage weld confidence article were welded in the Vertical Weld Center (VWC). For example, the RL10B-2 variant used on the ICPS has a three-cone nozzle extension which is partially deployed in-flight; the RL10C-3 for initial EUS use will have a fixed, two-cone extension that eliminates the deployment mechanisms. “So we made the decision some time ago that we were going to run sea-level engines — special test equipment engines, not the flight articles — for the Green Run.”, “Then we would ship the stage back to MAF, and we would swap the sea-level engines out for the flight article RL10s and then ship that to KSC.”. EUS is an upper stage that will operate in high-altitude/vacuum conditions; however, it was decided to configure the stage and the RL10 engines in particular for a sea-level test-firing at Green Run, which reduced the scope of the modifications necessary to convert B-2 to support EUS. The joint NASA-ESA Titan Saturn System Mission proposal envisioned the SLS as an option for launch. The EUS computer system will control the whole SLS vehicle through countdown, launch, ascent, and injection burns to destinations beyond Earth. Learn more about Artemis. NASA’s SLS Program and EUS prime contractor Boeing are preparing to begin construction of the test and flight articles that will be needed to certify and fly the new upper stage’s first launch. While the Critical Design Review for the stage is complete, Block 1B development efforts continue at Marshall as EUS manufacturing is slated to begin at Michoud in the Summer. NASA’s Space Launch System (SLS) rocket is designed to be flexible and evolvable to meet a variety of crew and cargo mission needs – and with an exploration upper stage (EUS) planned for future configurations, the rocket will require a new adapter to connect it to the Orion spacecraft. “It’s a mixed bag across the different [elements], [the] hydrogen tank, the different structural beams, LOX tank, thrust structure, propellant lines,” Scotty Sparks, deputy manager of NASA’s Block 1B/Exploration Upper Stage Development Office, explained. “EUS is kind of the long pole in the tent, but it’s not the only part involved in flying the Block 1B variant of the SLS vehicle,” Wofford said. NASA Exploration Upper Stage (EUS) will evolve the SLS to a sig nificantly higher performance level. Animation depicting NASA’s Space Launch System, the world's most powerful rocket for a new era of human exploration beyond Earth’s orbit. Sometimes we select it because of its availability or its cost or its availability in terms of where it is. Manufacturing and assembly development work for the Space Launch System (SLS) Exploration Upper Stage (EUS) is starting to ramp up at the Michoud Assembly Facility (MAF) in New Orleans. The Space Launch System (SLS) is an American Space Shuttle-derived super heavy-lift expendable launch vehicle, which has been under development by NASA in the United States since its announcement in 2011. “However, if we take the nozzle off and run it with a so-called ‘stub nozzle,’ then you can test the engine at sea-level with no problem.” Aerojet Rocketdyne tests single RL10 engines in a vacuum chamber at their Jupiter, Palm Beach County, Florida facilities. To do this, SLS has to have enough power to perform a maneuver known Like many rockets, the rocket’s propulsion is delivered in stages. The EUS structural elements will be an integrated assembly, in contrast to the over 200-foot long Core Stage, whose structural test articles were divided into separate test assemblies. The report accompanying the final fiscal year 2019 appropriations bill funding NASA directed that at least $150 million of the $2.15 billion provided for SLS be directed to work on the EUS. EUS is the major upgrade from the SLS Block 1 vehicle that will fly the program’s first three launches to the Block 1B configurations. “We deliver the completed stage ready for Green Run to Stennis in November of 2023,” Wofford said. (Photo Caption: An expanded view of the Block 1B vehicle showing the Orion and SLS elements that are assembled in the Crew configuration of the launcher. The EUS is to complete the SLS's ascent phase and then re-ignite to send its payload to destinations beyond low Earth orbit. A structural test article (STA) will be assembled at MAF and tested at the Marshall Space Flight Center (MSFC) in Huntsville, Alabama. We’re well on schedule in that area,” Wofford said. Aerojet Rocketdyne is developing a next-generation version of the engine called the RL10C-X that will make extensive use of additive manufacturing, also known as “3-D printing.” For the Block 1B vehicle, NASA is leaving extra room in the interstage for a C-X engine configuration with a longer nozzle than the C-3. The SLS rocket will carry astronauts and cargo aboard NASA’s spacecraft to the Moon and to other intermediary locations in space, where astronauts will build and begin testing the systems needed for challenging missions to other planetary and interplanetary destinations, including … NASA, Boeing looking to begin SLS Exploration Upper... Starship SN10 successfully lands before RUD’ing on the... China preparing to build Tiangong station in 2021,... Spacewalk successfully begins process of increasing Space Station’s... to the one that NASA and Boeing are currently trying to finish on the first SLS Core Stage. The EUS optimizes. "At this point, there is no path by which the Exploration Upper Stage will be ready for Artemis 3 in 2024," the NASA administration source told Ars. by Chris Gebhardt June 6, 2014. written by Chris Gebhardt June 6, 2014. Based on current forecasts, the structural test article (STA) would be delivered to Marshall at the beginning of 2023, where it would be placed in Test Stand 4697. NASA has extended Boeing's moon rocket assembly authorization in preparation to support as many as 10 moon missions for the agency's Artemis program, which aims to land astronauts on the moon in 2024. “So [there’s a] big integration effort involved in certifying and developing the new vehicle,” Wofford explained. So from the technical perspective, sometimes we select a certain alloy because of its performance. Boeing has already started fabrication activities that will support building the first EUS at NASA’s Michoud Assembly Facility in New Orleans. “So we’re in really good shape in terms of manufacturing facilities and capabilities.” The different structural elements are fabricated using different types of aluminum and aluminum-lithium alloys. An SLS rocket with the better upper stage almost certainly wouldn't be ready by 2024, and NASA knows this. [11], In 2014, NASA announced that it would proceed with development of Block 1B with the EUS,[12] and would use it on EM-2. Additionally, the SLS will serve as a back up for commercial and international partner transportation services to the … Some of the elements like the LOX tank use the aluminum 2219 alloy that is employed extensively on the Core Stage; other stage structural elements use aluminum-lithium alloys like 2050, 2070, and 2195. It would use the EUS hydrogen tank to build a 21st-century version of Skylab. After the weld is completed, large parts of the weld lands are cut out to perform destructive and non-destructive engineering evaluations of the welded material. Offering more payload mass, volume capabil- In 2023, the new. If you need immediate assistance, please contact the STI Program Information Desk. The NASA Scientific and Technical Information (STI) Program recently upgraded the NASA Technical Reports Server (NTRS), including NTRS-Registered, to enhance discoverability of, and access to, NASA-funded STI. The new upper stage will be outfitted with special test equipment versions of RL10 engines to conduct a sea-level test on engines designed to fire in a vacuum.). NASA confirms EUS for SLS Block IB design and EM-2 flight. EUS Green Run planned at Stennis before first launch. NASA’s SLS Program and EUS prime contractor Boeing are preparing to begin construction of the test and flight articles that will be needed to certify and fly the new upper stage’s first launch NASA EXPLORATION MISSION 2 MISSION DESIGN ... Exploration Mission 2 (EM-2) will be NASA’s first manned flight on the Space Launch System (SLS) and Orion Spacecraft. The EUS Green Run campaign will follow a similar outline of systematic checkouts, integrated testing, and a test-firing of the stage in the stand. EUS will increase the overall payload performance of SLS from about 27 metric tons to 38 metric tons when inserting the Orion spacecraft on a trans-lunar trajectory. How NASA Will Test Its SLS Rocket’s Core Stage. “The RL10 is an upper stage engine that’s designed and built to be run at altitude in a vacuum, so the nozzle is optimized to run in a vacuum, and you can’t run it at sea-level.”. Boeing announced Dec. 21 that the Exploration Upper Stage (EUS) of the SLS completed a critical design review with NASA. The VWC performs the vertical welds to join panels into a barrel assembly; the tooling is one of several at MAF that are being modified for the dual purpose of assembling both Core Stage and EUS hardware. The mission has been changed from an SLS Block 1B configuration to Block 1. Currently, SLS will use the Interim Cryogenic Propulsion Stage as its second stage built by United Launch Alliance (ULA) for its first few missions. “It’s complicated. The weld confidence test panels have the same key dimensions as full-scale articles in order to perform a full weld of two of them together. We appreciate your patience during this transition. This is a similar function to the S-IVB stage of the old Saturn V rocket. [2] In April 2016, it was reported that NASA has chosen to use a design based on four RL10-C3 engines for the EUS,[3] and in October 2016 NASA confirmed they had ordered 10 of the engines.
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