{"id":16539,"date":"2015-02-20T22:18:08","date_gmt":"2015-02-20T14:18:08","guid":{"rendered":"https:\/\/wp-productionenv-bjg9h2g2bgg5b8aa.southeastasia-01.azurewebsites.net\/news\/engineers-finding-lessons-in-nearly-flawless-orion-test-flight\/"},"modified":"2015-02-20T22:18:08","modified_gmt":"2015-02-20T14:18:08","slug":"engineers-finding-lessons-in-nearly-flawless-orion-test-flight","status":"publish","type":"post","link":"https:\/\/starpath.global\/news\/engineers-finding-lessons-in-nearly-flawless-orion-test-flight\/","title":{"rendered":"Engineers finding lessons in nearly flawless Orion test flight"},"content":{"rendered":"<figure id=\"attachment_4171\" aria-describedby=\"caption-attachment-4171\" style=\"width: 620px\" class=\"wp-caption alignnone\"><img fetchpriority=\"high\" decoding=\"async\" class=\" wp-image-4171\" src=\"http:\/\/spaceflightnow.com\/wp-content\/uploads\/2015\/02\/141205-N-GO855-110.jpg\" alt=\"The Orion spacecraft descends under three main parachutes at the end of its first mission into space Dec. 5. Credit: U.S. Navy Photo by Mass Communication Specialist 1st Class Charles White\" width=\"620\" height=\"505\" srcset=\"https:\/\/spaceflightnow.com\/wp-content\/uploads\/2015\/02\/141205-N-GO855-110.jpg 620w, https:\/\/spaceflightnow.com\/wp-content\/uploads\/2015\/02\/141205-N-GO855-110-300x244.jpg 300w\" sizes=\"(max-width: 620px) 100vw, 620px\"><figcaption id=\"caption-attachment-4171\" class=\"wp-caption-text\">The Orion spacecraft descends under three main parachutes at the end of its first mission into space Dec. 5. Credit: U.S. Navy Photo by Mass Communication Specialist 1st Class Charles White<\/figcaption><\/figure>\n<p>December\u2019s first orbital test flight of NASA\u2019s Orion crew capsule was almost perfect, but engineers are carefully analyzing 600 gigabytes of data recorded on the spacecraft\u2019s trip 3,600 miles into space to see how future missions to an asteroid and Mars could be improved.<\/p>\n<p>The data crunch will take much of the year, ultimately feeding into design tweaks and recommendations at a major Orion program review in the fourth quarter of 2015.<\/p>\n<p>The first phase of the data analysis is nearly complete, according to Mike Hawes, Orion\u2019s program manager at Lockheed Martin, NASA\u2019s prime contractor for the crew capsule.<\/p>\n<p>Hawes said Lockheed Martin, which led the execution of the Dec. 5 test flight on behalf of NASA, has given the space agency all the data recorded during the four-and-a-half hour mission.<\/p>\n<p>A final post-flight report on the Dec. 5 demo mission \u2014 dubbed Exploration Flight Test-1 \u2014 will be submitted to NASA in the first week of March, Hawes said Wednesday.<\/p>\n<p>Engineers are shifting from analyzing how the Orion spacecraft\u2019s systems functioned on the test flight to addressing how the capsule\u2019s performance \u2014 in areas that both exceeded and fell short of expectations \u2014 could help improve future missions.<\/p>\n<p>The next Orion mission is expected some time in 2018 aboard the first flight of NASA\u2019s Space Launch System, a mega-rocket made of upgraded space shuttle technology that will blast off from launch pad 39B at the Kennedy Space Center in Florida.<\/p>\n<p>The EFT-1 flight in December launched on a United Launch Alliance Delta 4-Heavy rocket and splashed down in the Pacific Ocean west of Mexico.<\/p>\n<p>The 2018 flight is named Exploration Mission-1, or EM-1, and will not carry astronauts. The first mission with a crew is scheduled for 2021 on the EM-2 flight.<\/p>\n<figure id=\"attachment_4173\" aria-describedby=\"caption-attachment-4173\" style=\"width: 620px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\" wp-image-4173\" src=\"http:\/\/spaceflightnow.com\/wp-content\/uploads\/2015\/02\/9556608236_d600564b79_z-2.jpg\" alt=\"Artist's concept of the Space Launch System with the Orion spacecraft. Credit: NASA\/MSFC\" width=\"620\" height=\"465\" srcset=\"https:\/\/spaceflightnow.com\/wp-content\/uploads\/2015\/02\/9556608236_d600564b79_z-2.jpg 640w, https:\/\/spaceflightnow.com\/wp-content\/uploads\/2015\/02\/9556608236_d600564b79_z-2-300x225.jpg 300w, https:\/\/spaceflightnow.com\/wp-content\/uploads\/2015\/02\/9556608236_d600564b79_z-2-326x245.jpg 326w, https:\/\/spaceflightnow.com\/wp-content\/uploads\/2015\/02\/9556608236_d600564b79_z-2-80x60.jpg 80w\" sizes=\"(max-width: 620px) 100vw, 620px\"><figcaption id=\"caption-attachment-4173\" class=\"wp-caption-text\">Artist\u2019s concept of the Space Launch System with the Orion spacecraft. Credit: NASA\/MSFC<\/figcaption><\/figure>\n<p>\u201cThere will probably be some continued analysis, but in my mind that continued analysis is really in terms of understanding the modifications that might be applicable to that next mission,\u201d Hawes said. \u201cThat\u2019s not so much (focusing) on EFT-1 and understanding what happened, it\u2019s more like do we need to do any changes for EM-1 and EM-2.\u201d<\/p>\n<p>The EM-1 and EM-2 flights will go around the moon, and the crewed mission will be the farthest voyage by astronauts since the last Apollo lunar landing in 1972.<\/p>\n<p>\u201cOrion\u2019s flight test was a big success and what we learned is informing how we design, develop and build future Orions that will help us pioneer deep space destinations,\u201d said Mark Geyer, NASA\u2019s Orion program manager. \u201cTaking a look at all the flight test data is a huge part of the development process and a key part off in why we flew a test flight. We have critical work happening this year, both on the data analysis and development side, to keep us moving toward our first mission with SLS.\u201d<\/p>\n<p>Orion\u2019s EFT-1 test flight demonstrated a new 3D-printed vent, and an analysis of how the component performed could lead to future Orion missions flying with more parts produced with a 3D printer instead of traditional machining.<\/p>\n<p>The Orion spacecraft consumed significantly less fuel than predicted thanks to an on-target injection from the Delta 4-Heavy launcher.<\/p>\n<p>Hawes said officials are considering ways to add more cameras to future missions after the Orion test flight produced spectacular imagery from start to finish \u2014 including rocket-mounted cameras during launch, views of Earth from 3,600 miles out, and the capsule\u2019s atmospheric re-entry inside a ball of plasma.<\/p>\n<p><iframe loading=\"lazy\" width=\"678\" height=\"381\" src=\"https:\/\/www.youtube.com\/embed\/1s_JnRQAnX0?feature=oembed\" frameborder=\"0\" allowfullscreen=\"\"><\/iframe><\/p>\n<p>\u201cWe certainly have learned you can\u2019t have enough cameras, so we\u2019re in the midst of trades on imagery right now in terms of the follow-on plan in how we incorporate more imagery,\u201d Hawes said.<\/p>\n<p>One blemish on the December test mission was in the crew module\u2019s airbags, which are supposed to flip the capsule upright if it splashes down nose first.<\/p>\n<p>Only two of the capsule\u2019s five bags fully inflated with high-pressure helium. Another airbag lost pressure soon after inflation, and two bags did not inflate at all.<\/p>\n<p>In the case of the EFT-1 splashdown, the Orion spacecraft landed in the correct orientation, and the bags were not needed.<\/p>\n<p>One earlier focus of the investigation into the airbag glitch was on threaded fittings inside the uprighting system\u2019s helium plumbing. Engineers considered whether the helium gas could escape through the threads, but Hawes told reporters Wednesday that the bags themselves may be at fault.<\/p>\n<p>\u201cParticularly on the two bags that didn\u2019t inflate, we\u2019re doing analysis now and it looks like perhaps there are problems with the bags themselves,\u201d Hawes said. \u201cWe\u2019ve looked at the plumbing, we\u2019ve looked at the gas supply system, and it looks perhaps like it may be issues with the bag material itself that had some small cracks develop that then prevented it from keeping pressure, but that\u2019s still preliminary.\u201d<\/p>\n<p>Hawes said Orion managers have not made final decision on redesigning the capsule\u2019s 16.5-foot diameter heat shield to correct cracking problems and workmanship concerns.<\/p>\n<p>The Orion spacecraft plunged back into the atmosphere at 20,000 mph \u2014 about 84 percent of the velocity it would see coming back from the moon \u2014 and weathered temperatures near 4,000 degrees Fahrenheit.<\/p>\n<figure id=\"attachment_4172\" aria-describedby=\"caption-attachment-4172\" style=\"width: 621px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\" wp-image-4172\" src=\"http:\/\/spaceflightnow.com\/wp-content\/uploads\/2015\/02\/2015-1020-m.jpg\" alt=\"The Orion spacecraft returned to the Kennedy Space Center in December after its four-and-a-half hour test flight. Credit: NASA\/Cory Huston\" width=\"621\" height=\"414\" srcset=\"https:\/\/spaceflightnow.com\/wp-content\/uploads\/2015\/02\/2015-1020-m.jpg 1000w, https:\/\/spaceflightnow.com\/wp-content\/uploads\/2015\/02\/2015-1020-m-300x200.jpg 300w, https:\/\/spaceflightnow.com\/wp-content\/uploads\/2015\/02\/2015-1020-m-768x512.jpg 768w\" sizes=\"auto, (max-width: 621px) 100vw, 621px\"><figcaption id=\"caption-attachment-4172\" class=\"wp-caption-text\">The Orion spacecraft returned to the Kennedy Space Center in December after its four-and-a-half hour test flight. Credit: NASA\/Cory Huston<\/figcaption><\/figure>\n<p>Avcoat insulation manually applied to 330,000 individual cells on the heat shield\u2019s fiberglass-phenolic honeycomb structure was supposed to ablate away during the Orion spacecraft\u2019s re-entry, protecting the underlying structure from searing temperatures.<\/p>\n<p>\u201cEvery single one of those cells is filled with the Avcoat material with a putty gun, then it\u2019s cured, formed and rounded,\u201d Hawes said. \u201cWhen you look at that honeycomb structure, you imagine that over this 16-foot diameter heat shield. Every single one of those gets filled with a caulk gun manually by a technician. That\u2019s one of our bigger concerns with the heat shield \u2014 just the long term manufacturing and to make it less touch intensive.\u201d<\/p>\n<p>The Orion heat shield\u2019s titanium skeleton and carbon fiber skin was fabricated by Lockheed Martin in Colorado. The skeleton was shipped to Textron Defense Systems in Massachusetts for installation of the honeycomb structure and filling of the Avcoat cells.<\/p>\n<p>NASA and Lockheed Martin may change the heat shield design for future Orion missions, using the same material but a different manufacturing method.<\/p>\n<p>Instead of attaching the heat shield to the capsule in one piece \u2014 called a \u201cmonolithic\u201d design \u2014 engineers are evaluating a switch to a \u201cblock\u201d approach using several pieces.<\/p>\n<p>\u201cWe knew that there some areas of the curvature that looked like they were lower strength than we had expected,\u201d Hawes said. \u201cAll of those areas survived the flight extremely well \u2026 That gives us some confidence in some of the shortcomings of what we thought about the monolithic structure. We\u2019re still worried overall over the manufacturability of the monolithic shape just because it\u2019s very hand touch labor intensive.\u201d<\/p>\n<p>The heat shield from the EFT-1 mission has been removed from the capsule and prepared for shipment to NASA\u2019s Marshall Space Flight Center in&nbsp;Alabama where the leftover Avcoat material will be scraped off. The titanium base of the heat shield will then go to NASA\u2019s Langley Research Center in Virginia for water impact testing, Hawes said.<\/p>\n<p>Hawes said Lockheed Martin and NASA are slated to discuss the future heat shield design in a few weeks.<\/p>\n<p><b><i>Follow Stephen Clark on Twitter: @StephenClark1.<\/i><\/b><\/p>\n","protected":false},"excerpt":{"rendered":"<p>The Orion spacecraft descends under three main parachutes at the end of its first mission into space Dec. 5. Credit: U.S. Navy Photo by Mass Communication Specialist 1st Class Charles White December\u2019s first orbital test flight of NASA\u2019s Orion crew capsule was almost perfect, but engineers are carefully analyzing 600 gigabytes of data recorded on [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"","ping_status":"","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"footnotes":"","_links_to":"","_links_to_target":""},"categories":[2],"tags":[3688,472,640],"class_list":["post-16539","post","type-post","status-publish","format-standard","hentry","category-news","tag-eft-1","tag-lockheed-martin","tag-orion"],"acf":[],"_links":{"self":[{"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/posts\/16539"}],"collection":[{"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/comments?post=16539"}],"version-history":[{"count":0,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/posts\/16539\/revisions"}],"wp:attachment":[{"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/media?parent=16539"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/categories?post=16539"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/tags?post=16539"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}