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By Space Force
Space Launch Delta 45 continued to “set the pace for space” as the world’s busiest spaceport in 2024. The SLD 45 team enabled 93 launches from the Eastern Range in 2024.
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By NASA
The NESC Mechanical Systems TDT provides broad support across NASA’s mission directorates. We are a diverse group representing a variety of sub-disciplines including bearings, gears, metrology, lubrication and tribology, mechanism design, analysis and testing, fastening systems, valve engineering, actuator engineering, pyrotechnics, mechatronics, and motor controls. In addition to providing technical support, the
TDT owns and maintains NASA-STD-5017, “Design and Development Requirements for Space Mechanisms.”
Mentoring the Next Generation
The NESC Mechanical Systems TDT actively participates in the Structures, Loads & Dynamics, Materials, and Mechanical Systems (SLAMS) Early Career Forum that mentors early-career engineers. The TDT sent three members to this year’s forum at WSTF, where early-career engineers networked with peers and NESC mentors, gave presentations on tasks they worked on at their home centers, and attended splinter sessions where they collaborated with mentors.
New NASA Valve Standard to Reduce Risk and Improve Design and Reliability
Valve issues have been encountered across NASA’s programs and continue to compromise mission performance and increase risk, in many cases because the valve hardware was not qualified in the environment as specified in NASA-STD-5017. To help address these issues, the Mechanical Systems TDT is developing a NASA standard for valves. The TDT assembled a team of subject matter experts from across the Agency representing several disciplines including mechanisms, propulsion, environmental control and life support systems, spacesuits, active thermal control systems, and materials and processes. The team has started their effort by reviewing lessons learned and best practices for valve design and hope to have a draft standard ready by the end of 2025.
Bearing Life Testing for Reaction Wheel Assemblies
The Mechanical Systems TDT just concluded a multiyear bearing life test on 40 motors, each containing a pair of all steel bearings of two different conformities or a pair of hybrid bearings containing silicon nitride balls. The testing confirmed that hybrid bearings outperformed their steel counterparts, and bearings with higher conformity (54%) outperformed bearings with lower conformity (52%). The team is disassembling and inspecting the bearings, and initial results have been surprising. The TDT was able to “recover” some of the bearings that failed during the life test and get them running as well as they did when testing began. Some bearings survived over five billion revolutions and appeared like new when they were disassembled and inspected. These results will be published once analysis is complete.
X-57 Design Assessment
The Mechanical Systems TDT was asked by the Aeronautics Mission Directorate to assess the design of the electric cruise motors installed on X-57. The team responded quickly to meet the Project’s schedule, making an onsite visit and attending numerous technical interchange meetings. After careful review of the design, the TDT identified areas for higher-level consideration and risk assessment and attended follow-on reviews to provide additional comments and advice.
CLARREO Pathfinder Inner Radial Bearing Anomaly
The Climate Absolute Radiance and Refractivity Observatory (CLARREO) Pathfinder was designed to take highly accurate measurements of reflected solar radiation to better-understand Earth’s climate. During payload functional testing, engineers detected a noise as the HySICS pointing system was rotated from its normal storage orientation. Mechanical Systems TDT members reviewed the design and inspection reports after disassembly of the inner bearing unit, noticing contact marks on the bore of the inner ring and the shaft that confirmed that the inner ring of the bearing was moving on the shaft with respect to the outer ring. Lubricant applied to this interface resolved the noise problem and allowed the project to maintain schedule without any additional costs.
JPL Wheel Drive Actuator Extended Life Test Independent Review Team
A consequence of changes to its mission on Mars will require the Perseverance Rover to travel farther than originally planned. Designed to drive 20 km, the rover will now need to drive ~91 km to rendezvous and support Mars sample tube transfer to the Sample Retrieval Lander. The wheel drive actuators with integral brakes had only been life tested to 40 km, so a review was scheduled to discuss an extended life test. The OCE Science Mission Directorate Chief Engineer assembled an independent review team (IRT) that included NESC Mechanical Systems TDT members. This IRT issued findings and guidance that questioned details of the JPL assumptions and plan. Several important recommendations were made that improved the life test plan and led to the identification of brake software issues that were reducing brake life. The life test has achieved 40 km of its 137 km goal and is ongoing. In addition, software updates were sent to the rover to improve brake life.
Orion Crew Module Hydrazine Valve
When an Orion crew module hydrazine valve failed to close, the production team asked the Mechanical Systems TDT for help. A TDT member attended two meetings and then visited the valve manufacturer, where it was determined this valve was a scaled-down version of the 12-inch SLS prevalve that was the subject of a previous NESC assessment and shared similar issues. The Orion Program requested NESC materials and mechanical systems support. The Mechanical Systems TDT member then worked closely with a Lockheed Martin (LM) Fellow for Mechanisms to review all the valve vendor’s detailed drawings and assembly procedures and document any issues. A follow-on meeting was held to brief both the LM and NASA Technical Fellows for Propulsion that a redesign and requalification was recommended. These recommendations have now been elevated to the LM Vice President for Mission Success and the LM Chief Engineer for Orion.
NASA’s Perseverance Mars rover selfie taken in July 2024.
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By NASA
NASA has taken a big step forward in how engineers will assemble and stack future SLS (Space Launch System) rockets for Artemis Moon missions inside the Vehicle Assembly Building (VAB) at the agency’s Kennedy Space Center in Florida.
The VAB’s High Bay 2 has been outfitted with new tooling to facilitate the vertical integration of the SLS core stage. That progress was on full display in mid-December when teams suspended the fully assembled core stage 225 feet in the air inside the high bay to complete vertical work before it is stacked on mobile launcher 1, allowing teams to continue solid rocket booster stacking simultaneously inside High Bay 3 for Artemis II.
The fully assembled SLS (Space Launch System) core stage for the Artemis II test flight is suspended 225 feet in the air inside the newly renovated High Bay 2 at Kennedy’s Vehicle Assembly Building. The core stage was lifted to enable engineers to complete work before it is stacked on mobile launcher 1 with other rocket elements. With the move to High Bay 2, technicians now have 360-degree tip to tail access to the core stage, both internally and externally.NASA With the move to High Bay 2, technicians with NASA and Boeing now have 360-degree tip to tail access to the core stage, both internally and externally. Michigan-based supplier Futuramic Tool and Engineering led the design and build of the Core Stage Vertical Integration Center tool that will hold the core stage in a vertical position.
“High Bay 2 tooling was originally scheduled to be complete for Artemis III. We had an opportunity to get it done earlier and that will put us in a good posture to complete work earlier than planned prior to moving the core stage for Artemis II into the full integrated stack over into in High Bay 3,” said Chad Bryant, deputy manager of the NASA SLS Stages Office. “This gives us an opportunity to go in and learn how to rotate, lift, and move the core stage into the high bay.”
This move also doubles the footprint of useable space within the VAB, giving engineers access to both High Bay 2 and High Bay 3 simultaneously, while also freeing up space at NASA’s Michoud Assembly Facility in New Orleans to continue work on the individual elements for future SLS core stages.
High Bay 2 has a long history of supporting NASA exploration programs: during Apollo, High Bay 2, one of four high bays inside the VAB, was used to stack the Saturn V rocket. During the Space Shuttle Program, the high bay was used for external tank checkout and storage and as an extra storage area for the shuttle.
Under the new assembly model beginning with Artemis III, all the major structures for the SLS core stage will continue to be fully produced and manufactured at NASA Michoud. Upon completion of manufacturing and thermal protection system application, the engine section will be shipped to Kennedy for final outfitting.
The 212-foot-tall SLS (Space Launch System) core stage for NASA Artemis II is seen being moved from a horizontal position to a vertical position in High Bay 2 at the Vehicle Assembly Building at NASA’s Kennedy Space Center in Florida. With the move to High Bay 2, NASA and Boeing technicians now have 360-degree access to the core stage both internally and externally. (NASA) “Core stage 3 marks a significant change in the way we build core stages,” said Steve Wofford, manager of the SLS Stages Office. “The vertical capability in High Bay 2 allows us to perform parallel processing from the top to bottom of the stage. It’s a much more efficient way to build core stages. This new capability will streamline final production efforts, allowing our team to have 360-degree access to the stage, both internally and externally.”
The fully assembled core stage for Artemis II arrived July 23, 2024, at Kennedy, where it remained horizontal inside the VAB transfer aisle until its recent lift into the newly outfitted high bay.
Teams at NASA Michoud are outfitting the remaining core stage elements for Artemis III and preparing to horizontally join them. The four RS-25 engines for the Artemis III mission are complete at NASA’s Stennis Space Center in Bay St. Louis, Mississippi, and will be transported to NASA Kennedy in 2025. Major core stage and exploration upper stage structures are in work at NASA Michoud for Artemis IV and beyond.
NASA is working to land the first woman, first person of color, and its first international partner astronaut on the Moon under Artemis. SLS is part of NASA’s backbone for deep space exploration, along with the Orion spacecraft, supporting ground systems, advanced spacesuits and rovers, the Gateway in orbit around the Moon, and commercial human landing systems. SLS is the only rocket that can send Orion, astronauts, and supplies to the Moon in a single launch.
News Media Contact
Jonathan Deal
Marshall Space Flight Center
Huntsville, Ala.
256-544-0034
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