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Vary that thrust: longer hot-fire of rocket engine demonstrator
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By NASA
NASA’s Jason Hopper is shown at the E Test Complex at NASA’s Stennis Space Center.NASA/Danny Nowlin Jason Hopper’s journey to NASA started with assessing the risk of stepping into the unknown.
One day, while taking a break from his hobby of rock climbing at Mississippi State University, a fellow student noticed Hopper reading a rocket propulsion textbook with a photo of a space shuttle launch on the cover.
Rocket propulsion – the technology that propels vehicles into space, usually through liquid rocket engines or solid rocket motors – is a highly complex field. Engineers rigorously test the propulsion systems and components to understand their capabilities and limitations, ensuring rockets can safely reach space.
“A guy just walked up and randomly said, ‘Hey, my dad works testing rocket engines,’” Hopper recalled.
Hopper, an aerospace engineering student at the time, did not know about NASA’s Stennis Space Center near Bay St. Louis, Mississippi. He soon would learn more.
The fellow student provided him with contact information, and the rest is history.
A Meridian, Mississippi, native, Hopper graduated from Mississippi State in 2007 and made his way to America’s largest rocket propulsion test site in south Mississippi.
On the other side of Hopper’s risk of stepping into the unknown came the reward of realizing how far he had come from reading about rocket propulsion work to contributing to it.
The career highlight happened when Hopper watched a space shuttle launch, powered in part by an engine he had fired up as a test conductor working at NASA Stennis.
“You cannot really put it into words because it permeates all through you, knowing that you are a part of something that big while at the same time, you are just a little piece of it,” he said.
Hopper transitioned from his contractor position to a civil servant role as test conductor when he joined NASA in 2011.
His work as a test conductor throughout all the NASA Stennis test areas and as test director at the E Test Complex has benefited NASA and industry, while giving him a good perspective on the value of the center’s work.
Among the projects he has played a large role in include the J-2X engine test program, build up for NASA’s SLS (Space Launch System) core stage hot fire ahead of the successful Artemis I launch and multiple projects throughout the E Test Complex.
“We offer operational excellence that I would argue you cannot get anywhere else,” Hopper said. “NASA Stennis is a smaller, family-oriented center renowned for excellence in rocket propulsion testing. It is a small place, where we do amazing things.”
Propulsion test customers at NASA Stennis include government and commercial projects. The NASA center is engaged in two projects to support the agency’s SLS rocket – testing of RS-25 engines to help power SLS launches and of NASA’s new exploration upper stage to fly on future missions to the Moon.
Current commercial companies conducting work at NASA Stennis include Blue Origin; Boeing; Evolution Space; Launcher, a Vast company; Relativity Space; and Rolls-Royce. Three companies – Relativity Space, Rocket Lab, and Evolution Space – are establishing production and/or test operations onsite.
After leaving south Mississippi for a four-year stint at NASA’s Marshall Spaceflight Center in Huntsville, Alabama, Hopper returned to NASA Stennis as risk manager of NASA’s Rocket Propulsion Test Program Office.
In his day-to-day work, Hopper assesses risk around two questions – what is the risk and what do I really need to be focusing on?
Making decisions through this filter helps the Poplarville, Mississippi, resident make the best use of the agency’s rocket propulsion test assets, activities, and resources.
“With a risk perspective, if things are high risk, we need to address these items and focus our attention on them,” Hopper said. “If we lose a national test capability, that impacts more than just NASA; it impacts the nation because NASA is a significant enabler of commercial spaceflight.”
Hopper helps oversee the maintenance and sustainment of propulsion test capabilities across four sites – NASA Stennis; NASA Marshall; NASA’s Neil Armstrong Test Facility in Sandusky, Ohio; and NASA’s White Sands Test Facility in Las Cruces, New Mexico.
By establishing and maintaining world-class test facilities, the agency’s Rocket Propulsion Test Program Office ensures that NASA and its partners can conduct safe, efficient, and cost-effective rocket propulsion tests to support the advancement of space exploration and technology development.
Hopper looks to the future with optimism.
“We have an opportunity to redefine kind of what we as NASA and NASA Stennis do and how we do it,” he said. “Before, we were trying to help commercial companies figure things out. We were trying to get them up and going, but now we are in more of a support role in a lot of ways and so if you look at it, and approach it the right way, it can be very exciting.”
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By NASA
6 Min Read NASA Stennis Flashback: Learning About Rocket Engine Smoke for Safe Space Travel
An image shows engineers at an early version of the test stand at the Diagnostic Testbed Facility. From 1988 to the mid-1990s, NASA Stennis engineers operated the facility to conduct rocket engine plume exhaust diagnostics and learn more about the space shuttle main engine combustion process. Credits: NASA/Stennis NASA’s Stennis Space Center near Bay St. Louis, Mississippi, is widely known as the nation’s largest rocket propulsion test site. More than 35 years ago, it also served as a hands-on classroom for NASA engineers seeking to improve the efficiency of space shuttle main engines.
From 1988 to the mid-1990’s, NASA Stennis engineers operated a Diagnostic Test Facility to conduct rocket engine plume exhaust diagnostics and learn more about the space shuttle main engine combustion process. The effort also laid the groundwork for the frontline research-and-development testing conducted at the center today.
“The Diagnostic Test Facility work is just another example of the can-do, will-do attitude of the NASA Stennis team and of its willingness to support the nation’s space exploration program in all ways needed and possible,” said Joe Schuyler, director of the NASA Stennis Engineering and Test Directorate.
The Diagnostic Test Facility work is just another example of the can-do, will-do attitude of the NASA Stennis team…
joe schuyler
NASA Stennis Engineering and Test Directorate Director
Tests conducted at the Diagnostic Testbed Facility played a critical safety role for engine operations and also provided a real-time opportunity for NASA Stennis engineers to learn about exhaust diagnostics. NASA/Stennis An image shows the Diagnostic Testbed Facility test stand data acquisition trailer. NASA/Stennis The Need
Envision a rocket or space vehicle launching into the sky. A trail of bright exhaust, known as the engine plume, follows. As metals wear down in the engines from the intense heat of the combustion process, the flame glows with colors, some visible, such as orange or yellow, and others undetectable by the human eye.
The colors tell a story – about the health and operation of the engine and its components. For space shuttle main engines, which flew on multiple missions, engineers needed to understand that story, much as a doctor needs to understand the condition of a human body during checkup, to ensure future engine operation.
Where better place to study such details than the nation’s premier propulsion test site? Paging NASA Stennis.
An image shows the rocket motor and thruster at the Diagnostic Testbed Facility. NASA/Stennis An image shows the Diagnostic Testbed Facility blended team of NASA personnel and contractors. Kneeling, left to right, is Brantly Adams (NASA), Felix Bircher (Sverdrup Technology), Dennis Butts (Sverdrup Technology), and Nikki Raines (Sverdrup Technology). Standing, left to right, NASA astronaut John Young, Greg Sakala (Sverdrup Technology), Barney Nokes (Sverdrup Technology), John Laboda (Sverdrup Technology), Glenn Varner (NASA), Stan Gill (NASA), Bud Nail (NASA), Don Sundeen (Sverdrup Technology), NASA astronaut John Blaha.NASA/Stennis The Facility
NASA Stennis has long enabled and supported innovative and collaborative work to benefit both the agency and the commercial space industry. When NASA came calling in the late 1980s, site engineers went to work on a plan to study space shuttle main engine rocket exhaust.
The concept for an enabling structure about the size of a home garage was born in October 1987. Five months later, construction began on a Diagnostic Testbed Facility to provide quality research capabilities for studying rocket engine exhaust and learning more about the metals burned off during hot fire.
The completed facility featured a 1,300-square-foot control and data analysis center, as well as a rooftop observation deck. Small-scale infrastructure was located nearby for testing a 1,000-pound-thrust rocket engine that simulated the larger space shuttle main engine. The 1K engine measured about 2 feet in length and six inches in diameter. Using a small-scale engine allowed for greater flexibility and involved less cost than testing the much-larger space shuttle engine.
An image shows Sverdrup Technology’s Robert Norfleet as he preps the dopant injection system for testing at the Diagnostic Testbed Facility. The goal of the facility was to inject known metals and materials in a chemical form and then look at what emissions were given off. During one test, generally a six or 12 second test, operators would inject three known dopants, or substances, and then run distilled water between each test to clean out the system.NASA/Stennis An image shows engineers Stan Gill, Robert Norfleet, and Elizabeth Valenti in the Diagnostic Testbed Facility test control center. NASA/Stennis The Process
Engineers could quickly conduct multiple short-duration hot fires using the smaller engine. A six-second test provided ample time to collect data from engine exhaust that reached as high as 3,900 degrees Fahrenheit.
Chemical solutions simulating engine materials were injected into the engine combustion chamber for each hot fire. The exhaust plume then was analyzed using a remote camera, spectrometer, and microcomputers to determine what colors certain metals and elements emit when burning.
Each material produced a unique profile. By matching the profiles to the exhaust of space shuttle main engine tests conducted at NASA Stennis, determinations could be made about which engine components were undergoing wear and what maintenance was needed.
We learned about purging, ignition, handling propellants, high-pressure gases, and all the components you had to have to make it work…It was a very good learning experience.
Glenn Varner
NASA Stennis Engineer
The Benefits
The Diagnostic Testbed Facility played a critical safety role for engine operations and also provided a real-time opportunity for NASA Stennis engineers to learn about exhaust diagnostics.
Multiple tests were conducted. The average turnaround time between hot fires was 18 to 20 minutes with the best turnaround from one test to another taking just 12 minutes. By January 1991, the facility had recorded a total of 588 firings for a cumulative 3,452 seconds.
As testing progressed, the facility team evolved into a collection of experts in plume diagnostics. Longtime NASA Stennis engineer Glenn Varner serves as the mechanical operations engineer at the Thad Cochran Test Stand, where he contributed to the successful testing of the first SLS (Space Launch System) core stage onsite.
However, much of Varner’s hands-on experience came at the Diagnostic Test Facility. “We learned about purging, ignition, handling propellants, high-pressure gases, and all the components you had to have to make it work,” he said. “It was a very good learning experience.”
An image shows the Diagnostic Testbed Facility team working in the test control center. Seated, left to right, is Steve Nunez, Glenn Varner, Joey Kirkpatrick. Standing, back row left to right, is Scott Dracon and Fritz Policelli. Vince Pachel is pictured standing wearing the headset. NASA/Stennis The physical remnants of the Diagnostic Testbed Facility are barely recognizable now, but that spirit and approach embodied by that effort and its teams continues in force at the center.
joe schuyler
NASA Stennis Engineering and Test Directorate Director
The Impact
The Diagnostic Testbed Facility impacted more than just those engineers involved in the testing. Following the initial research effort, the facility underwent modifications in January 1993. Two months later, facility operators completed a successful series of tests on a small-scale liquid hydrogen turbopump for a California-based aerospace company.
The project marked an early collaboration between the center and a commercial company and helped pave the way for the continued success of the NASA Stennis E Test Complex. Building on Diagnostic Testbed Facility knowledge and equipment, the NASA Stennis complex now supports multiple commercial aerospace projects with its versatile infrastructure and team of propulsion test experts.
“The physical remnants of the Diagnostic Testbed Facility are barely recognizable now,” Schuyler said. “But that spirit and approach embodied by that effort and its teams continues in force at the center.”
Additional Information
NASA Stennis has leveraged hardware and expertise from the Diagnostic Testbed Facility to provide benefit to NASA and industry for two decades and counting.
The facility’s thruster, run tanks, valves, regulators and instrumentation were used in developing the versatile four-stand E Test Complex at NASA Stennis that includes 12 active test cell positions capable of various component, engine, and stage test activities.
“The Diagnostic Testbed Facility was the precursor to that,” said NASA engineer Glenn Varner. “Everything but the structure still in the grass moved to the E-1 Test Stand, Cell 3. Plume diagnostics was part of the first testing there.”
When plume diagnostic testing concluded at E-1, equipment moved to the E-3 Test Stand, where the same rocket engine used for the Diagnostic Testbed Facility has since performed many test projects.
The Diagnostic Testbed Facility thruster also has been used for various projects at E-3, most recently in a project for the exploration upper stage being built for use on future Artemis missions.
In addition to hardware, engineers who worked at the Diagnostic Testbed Facility also moved on to support E Test Complex projects. There, they helped new NASA engineers learn how to handle gaseous hydrogen and liquid hydrogen propellants. Engineers learned about purging, ignition, and handling propellants and all the components needed for a successful test.
“From an engineering perspective, the more knowledge you have of the processes and procedures to make propulsion work, the better off you are,” Varner said. “It applied then and still applies today. The Diagnostic Testbed Facility contributed to the future development of NASA Stennis infrastructure and expertise.”
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Last Updated Feb 25, 2025 EditorNASA Stennis CommunicationsContactC. Lacy Thompsoncalvin.l.thompson@nasa.gov / (228) 688-3333LocationStennis Space Center Related Terms
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NASA/Kim Shiflett Engineers at NASA’s Kennedy Space Center in Florida completed stacking the twin SLS (Space Launch System) solid rocket boosters – seen in this Feb. 19, 2025, photo – inside the Vehicle Assembly Building for the agency’s Artemis II crewed test flight around the Moon.
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Image credit: NASA/Kim Shiflett
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By NASA
2 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
NASA marked a key milestone Feb. 18 with installation of RS-25 engine No. E20001, the first new production engine to help power the SLS (Space Launch System) rocket on future Artemis missions to the Moon.
The engine, built by lead SLS engines contractor L3Harris (formerly Aerojet Rocketdyne), was installed on the Fred Haise Test Stand in preparation for acceptance testing next month. It represents the first of 24 new flight engines being built for missions, beginning with Artemis V.
Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin Teams at NASA’s Stennis Space Center deliver, lift, and install the first new production RS-25 engine on the Fred Haise Test Stand on Feb. 18.NASA/Danny Nowlin The NASA Stennis test team will conduct a full-duration, 500-second hot fire, providing critical performance data to certify the engine for use on a future mission. During missions to the Moon, RS-25 engines fire for about 500 seconds and up to the 111% power level to help launch SLS, with the Orion spacecraft, into orbit.
The engine arrived at the test stand from the L3Harris Engine Assembly Facility on the engine transport trailer before being lifted onto the vertical engine installer (VEI) on the west side deck. After rolling the engine into the stand, the team used the VEI to raise and secure it in place.
The upcoming acceptance test follows two certification test series that helped verify the new engine production process and components meet all performance requirements. Four RS-25 engines help launch SLS, producing up to 2 million pounds of combined thrust.
All RS-25 engines for Artemis missions are tested and proven flightworthy at NASA Stennis prior to use. RS-25 tests are conducted by a team of operators from NASA, L3Harris, and Syncom Space Services, prime contractor for site facilities and operations.
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