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The tests \u2013 originally for the Ares 1 first stage \u2013 have been realigned ahead of their use on the SLS, which will debut at the end of 2017 as the Block 1 configuration.<\/p>\n
This initial capability Heavy Lift Launch Vehicle (HLV) will consist of a core stage using four Pratt and Whitney Rocketdyne (PWD) RS-25Ds \u2013 formerly used by the Shuttle Program \u2013 two ATK five segment Solid Rocket Boosters (SRBs) and an Interim Cryogenic Propulsion Stage (ICPS), highly likely to be a Delta Cryogenic Second Stage (DCSS).<\/p>\n
Three static fire tests have already taken place on the five segment boosters, all with a single span located in the middle of the booster.<\/p>\n
![\"Screenshot](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2013\/01\/A3171.jpg\" "\\"Screenshot")
The most recent test \u2013 DM-3 \u2013 took place in 2011 and was the last in a series of development motors to be tested. It was also the most heavily instrumented solid rocket motor in NASA history, with a total of 37 test objectives measured through more than 970 instruments.<\/p>\nAerospace industry analysis
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(Image taken from the amazing 220mb super slow-mo DM-3 Five Seg Motor Ground Test Video \u2013 available in L2 \u2013 LINK).<\/p>\n
The previous test \u2013 DM-2 in 2010 \u2013 was carried out with a total of 53 design objectives, measured through more than 760 instruments. For that test, the motor was cooled to 40 degrees F \u2013 a \u201ccold motor\u201d test \u2013 in order to measure solid rocket motor performance at low temperature, as well as to verify design requirements of new materials in the motor joints.<\/p>\n
![\"DM-3](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2013\/01\/Z52-350x205.jpg\" "\\"DM-3")
The DM-3 incorporated several performance-based improvements to the designs of the first two development motors. Additionally, the core of DM-3 was heated to 90 degrees Fahrenheit for this full-duration firing to verify the motor\u2019s performance at high temperatures.<\/p>\nATK are already deep into preparations for the first qualification firing of the five segment booster, with QM-1.<\/p>\n
It is expected that the five segment solid motor will be used on all SLS flights until at least the middle of the 2020s, with source information noting SLS managers have the option to launch up to 10 missions using the current five segment booster design.<\/p>\n
QM Mid Span Supports:<\/p>\n
QM-1 \u2013 and the follow on QM-2 \u2013 will both be fired at ATK Propulsion Systems base in Promontory, Utah. However, there will be a visual difference from previous firings, with the debut of two mid-span supports to further decrease motor sag to more closely simulate a vertical flight motor.<\/p>\n
![\"SAE](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2013\/03\/Z419.jpg\" "\\"SAE")
After ATK determined the need for a second mid-span support, they contracted with the same vendors that fabricated the first mid-span.<\/p>\nThe three major vendors for mid-span support include Major Tool and Machine from Indiana, Force Measurement Systems (FMS) of California, and Specialized Analysis Engineering (SAE) of Utah.<\/p>\n
The mid-span structures include two uprights bolted to the floor and a structure that spans the width of the static test motor and supports the weight taken up by the slings during build-up and testing.<\/p>\n
![\"A](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2013\/03\/Z322.jpg\" "\\"A")
The engineers at FMS manufactured the structure load cells and flexures used to support the sling, while the SAE team designed and built the control system for the support.<\/p>\nSAE are currently in the process of wiring and programming the control system \u2013 just as they did with the first mid-span support used for the DM static test motors.<\/p>\n
The system uses a custom programmable logic controller to control the electric motors and also receive load cell data.<\/p>\n
\u201cThese suppliers have a long-standing history with ATK and have once again proven their worth as deserving partners. We appreciate their ability to perform as required,\u201d noted Fred Brasfield, vice president, Next-generation Booster.<\/p>\n
\u201cThese vendors have supplied the components and structures needed to help obtain necessary data from our test motors.\u201d<\/p>\n
QM-1 Delay:<\/p>\n
Preparations for the upcoming QM-1 test began with the first casting operation of the Forward Segment back in July 16, 2012 at ATK\u2019s Promontory facility.<\/p>\n
![\"QM-1](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2013\/03\/Z518.jpg\" "\\"QM-1")
Casting operations continued without issue, with the Center\/Forward segment casting operations beginning in August of 2012.<\/p>\nSLS L2 Update Section did, however, note a few issues that had to be worked during the development schedule, one relating to the replacement of the ultrasonic sensor instrumentation in the QM-1 nozzle, and another involving the new over\/under speed protection (GTx) feature of the Electrical Ground Support Equipment (EGSE).<\/p>\n
\u201cA continuity failure of one sensor following nozzle assembly initiated an investigation revealing out of spec connector assemblies to several sensors. The decision has been made to re-terminate all 20 ultrasonic sensor connectors and re-assemble the Nozzle,\u201d noted the updates.<\/p>\n
\u201cThe second issue \u2013 specific to the GTx \u2013 relates to flight acceptance testing. The early development of the GTx allows multiple hot-fire exposures prior to deployment to KSC and buys down significant flight schedule risk. Initial testing of the GTx revealed an unacceptable sensitivity to noise, which will required modification.<\/p>\n
Click here for another Solid Rocket Booster\/Motor Articles: http:\/\/www.nasaspaceflight.com\/tag\/srb\/<\/p>\n
The GTx design was then verified during a hot-fire dry-run known as the Flight Control Test -2 (FCT-2), which took place earlier this year.<\/p>\n
This key avionics and controls test included a \u201chot fire\u201d of the fully integrated heritage TVC (Thrust Vector Control), the new SLS booster avionics subsystem and new EGSE.<\/p>\n
![\"FCT-2\"](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2013\/03\/Z67.jpg\" "\\"FCT-2\\"")
The test \u2013 of which an impressive video was made available \u2013 showed the TVC\u2019s systems purring into life during the FCT-2 countdown, prior to the actual firing of the SRM Ignition Initiators at T-0, simulating an actual lift-off. This was followed by the TVC systems gimballing the nozzle (not in place) on the hot fire aft skirt.<\/p>\n\u201cThe FCT-2 test marked a definite milestone for ATK and NASA\u2019s SLS program,\u201d added Mr Brasfield. \u201cWorking with Marshall, we have designed and developed a modern system and common interface that allows for multiple uses of the same equipment at all necessary locations for both qualification and operational phases of the program, greatly reducing complexity and costs.\u201d<\/p>\n
QM-1 had already slipped from its initial schedule of conducting the static test in May by the time of the FCT-2 success, with the latest estimate showing the firing of the QM-1 will be no sooner than November.<\/p>\n
![\"Slide](\"https:\/\/www.nasaspaceflight.com\/wp-content\/uploads\/2013\/03\/Z74.jpg\" "\\"Slide")
The slip to the end of the year is in part related to an issue with the aft segment of the QM-1, which was found to have about a two foot-wide area where propellant had debonded from the inside of the segment wall.<\/p>\nAfter some analysis \u2013 which found no voids in the actual propellant \u2013 NASA decided to ask ATK to scrap the segment and cast a replacement.<\/p>\n
The delay holds no impact on the schedule for the second static test \u2013 QM-2 \u2013 or the schedule towards the EM-1 flight in 2017, due more than a year of margin.<\/p>\n
(Images: Via ATK and L2 content from L2\u2019s SLS specific L2 sections, which includes, presentations, videos, graphics and internal \u2013 interactive with actual SLS engineers \u2013 updates on the SLS and HLV, available on no other site.)<\/p>\n
(L2 is \u2013 as it has been for the past several years \u2013 providing full exclusive SLS and Exploration Planning coverage. To join L2, click here: http:\/\/www.nasaspaceflight.com\/l2\/)<\/p>\n
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ATK will use two \u201cmid-span\u201d supports on their upcoming static test of their five segment Solid Rocket Booster (SRB). The large pieces of hardware will help mitigate \u201csagging\u201d in the motor, as it is tested in the horizontal position. The test \u2013 known as Qualification Motor -1 (QM-1) \u2013 has been slightly delayed to later […]<\/p>\n","protected":false},"author":1,"featured_media":30399,"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":[4144,9034,624,7806],"class_list":["post-39882","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news","tag-atk","tag-hlv","tag-sls","tag-srb"],"acf":[],"_links":{"self":[{"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/posts\/39882"}],"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=39882"}],"version-history":[{"count":0,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/posts\/39882\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/media\/30399"}],"wp:attachment":[{"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/media?parent=39882"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/categories?post=39882"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/starpath.global\/blog\/wp-json\/wp\/v2\/tags?post=39882"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}