NASA's next moon spacecraft for humans made one small leap into an altitude chamber for vital testing before it brings astronauts on board. The Orion spacecraft for Artemis 2 is slated to fly around the moon with four astronauts no earlier than September 2025 — but first, engineers with NASA want to make sure it is ready for the job. Testing in a vacuum chamber at NASA's Kennedy Space Center began Wednesday (April 10) to assess Orion for "electromagnetic interference and electromagnetic compatibility," NASA officials wrote in a statement. The aim is to make sure the spacecraft can continue working well amid these fields, both spacecraft-generated and space-generated, ahead of the big launch day. The four Artemis 2 astronauts who will fly around the moon aboard Orion are NASA commander Reid Wiseman, NASA pilot Victor Glover (who will become the first Black person to leave low Earth orbit, or LEO), NASA mission specialist Christina Koch (the first woman to go beyond LEO) and Canadian Space Agency mission specialist Jeremy Hansen (the first non-American to achieve the feat). Their spacecraft, now at KSC's Neil A. Armstrong Operations and Checkout Building, is inside a chamber with a lot of moon heritage. It was used to "test environmental and life support systems on the lunar and command modules during the Apollo program" that brought nine astronaut crews to the moon between 1968 and 1972, NASA officials wrote.
The Artemis 2 moon spacecraft lifts into an altitude chamber at NASA's Kennedy Space Center on April 4, 2024. The Orion spacecraft will undergo electromagnetic compatibility and interference testing inside the chamber at the Operations and Checkout Building. (Image credit: NASA/Amanda Stevenson)
The Artemis 2 moon astronauts pose in the well deck of the USS San Diego during recovery exercises on Feb. 25, 2024. From left: Canadian Space Agency mission specialist Jeremy Hansen, NASA mission specialist Christina Koch, NASA pilot Victor Glover and NASA commander Reid Wiseman. (Image credit: NASA/Isaac Watson)
There are multiple altitude chambers available at KSC; Orion is in the west chamber, which was upgraded to "test the spacecraft in a vacuum environment that simulates an altitude of up to 250,000 feet (76.2 km)," NASA wrote.
Technicians hoisted Orion into that chamber on April 4 using a newly installed 30-ton crane in the building, which can move the stacked Orion crew and service modules into the chamber, manipulate the lid of the chamber and carefully transfer the spacecraft in the building's high bay.
While Orion spacecraft have flown to space twice before, this mission will be the first with astronauts on board. It will also test new systems, such as life support. (The spacecraft model's previous journeys were the Artemis 1 uncrewed mission to lunar orbit in late 2022 and a brief trip to Earth orbit in 2014.)
Artemis 2's Orion has more work in store after the altitude chamber. It will next be sent to another zone, called Final Assembly and Systems Testing, in the same KSC building. Then, more altitude testing will happen "to conduct a test that simulates as close as possible the conditions in the vacuum of deep space," NASA wrote. Those altitude tests could begin as soon as this summer.
Artemis 2 will kick off the larger crewed Artemis program, which plans to put boots on the moon again with Artemis 3 as soon as 2026. Both missions were delayed in January 2024 due to technical issues; Artemis 2 was pushed back about nine months while Artemis 3 is forecast to wait an extra year.
The NASA-led Artemis program is eventually slated to put a settlement at the moon's south pole, near water resources that exist there.
The Artemis Accords include 35 countries committing to peaceful space exploration norms led by NASA; a subset of those countries, including Canada, are providing hardware for moon missions. Japan, another signatory to Artemis, committed to a pressurized lunar rover for astronauts and will be the first country other than the United States to land an astronaut on the moon, NASA and Japan announced on Wednesday (April 10).
As the Artemis 1 mission nears its conclusion, European Space Agency and industry officials praised the performance of the Orion spacecraft’s service module, which some see as a step towards a European crewed spacecraft. The Artemis 1 mission is set to conclude Dec. 11 with the reentry and splashdown of the Orion crew capsule, shortly after it separates from the European Service Module. That module provided power, propulsion and other services for the spacecraft since its Nov. 16 launch. “We are coming towards the end of what you might think of as a 100-meter race that’s followed a marathon,” said David Parker, ESA’s director for human and robotic exploration, during a Dec. 9 briefing. “The marathon was the 10 years of effort and preparation needed to build and prepare the first European Service Module for its journey to the moon and back again, and 100-meter race has been that actual mission itself.” During that 100-meter sprint, the service module has not broken stride. “The mission has gone really perfect from our point of view,” said Ralf Zimmermann, head of moon programs and the Orion European Service Module at Airbus, the prime contractor for the module. “We have absolutely flown a perfect mission so far.” There have been minor issues with the module, he noted, “but nothing mission critical.” One persistent issue has been with devices called latching current limiters in one part of the spacecraft’s power system. Those devices, similar to circuit breakers, have opened at least 17 times during the course of the mission without being commanded to do so, NASA officials said at a Dec. 8 briefing, but have not significantly affected spacecraft operations.
A view of the aft section of the European Service Module of the Orion spacecraft taken as the Artemis 1 mission nears its conclusion. Credit: NASA
“It’s not a big deal because they can be recommanded on,” said Philippe Deloo, ESA program manager for the service module. “We don’t have an idea of what is the root cause. We are investigating, looking at all possible options.”
One possibility, he said, is that electromagnetic interference or noise in the power system is causing the latching current limiters to open. Another possibility is they are being affected by transmissions from spacecraft antennas. Engineers are doing as much testing as they can before the end of the mission to identify the cause. “This is going to be a difficult one to troubleshoot.”
Zimmermann emphasized the issue was not serious. “When they open uncommanded, the effect on the mission is not that big,” he said, noting it affects only one of eight power lines on the spacecraft. “It is a glitch, not a mission-critical failure.”
Other parts of the European Service Module have exceeded expectations. The spacecraft is producing more power than expected, yet using less power than planned. Deloo said the reduced power consumption is, in turn, linked to the spacecraft dissipating less heat than expected, meaning it has to use heaters less frequently to maintain its proper temperature. “This is one of the major lessons learned.”
The service module has also produced many of the stunning images and video the mission has returned, thanks to GoPro cameras mounted on the tips of each of the four solar arrays. “We are calling them now four selfie sticks,” quipped Matthias Gronowski, chief engineer for the European Service Module at Airbus.
The Artemis 1 mission, and excellent performance of its service modules, comes as some in Europe advocate for ESA to develop its own human spaceflight capability. Human spaceflight was one of the long-term “inspirator” concepts endorsed by ESA member states a year ago, and remains a topic of debate in Europe.
“We have to see how far politicians are willing to look into this,” ESA Director General Josef Aschbacher said in a Dec. 1 speech at a Space Transportation Association luncheon here, noting the topic would come up at a second European “space summit” scheduled for late 2023. “Does Europe want to be more independent, more autonomous in human space transportation?”
“In terms of technical capability, can Europe build a human-rated space vehicle? I don’t doubt it,” Parker said, citing the success not just of the Artemis 1 mission but work on International Space Station modules and elements of the future lunar Gateway. What would be needed, he said, was experience in end-to-end operations of a crew spacecraft and development of safety systems, like a launch abort system, as well as a human-rated launch vehicle.
During the International Astronautical Congress in September, ArianeGroup released a concept for a vehicle called Smart Upper Stage for Innovative Exploration (SUSIE). The vehicle is designed to be a new, reusable upper stage for the Ariane 6 rocket, but could be used as a cargo and crew transportation vehicle. Morena Bernardini, head of strategy and innovation at ArianeGroup, said in an interview at the conference that a cargo version of SUSIE could be ready as soon as 2030 followed by a crewed version “immediately after.”
At the briefing, Zimmerman suggested Airbus was more interested in working with others, along the lines of the existing partnership on Orion, than developing a European crewed vehicle. “We need to unite forces and share the costs,” he said, noting he was offering his personal opinion. “This is, to me, much more important than saying its Germany, France, England or Europe in total against the Americans.”
Parker said the success of the service module shows ESA is ready for the next phases of Artemis. “We learned that we can send a crew-rated capsule to the moon and back again on its first flight, and that means it gives us a lot of confidence to go forward in the next steps in Artemis.”
ESA has a contract with Airbus to produce service modules through Artemis 6, at a total value of a little more than two billion euros. ESA’s member states approved plans to produce three more service modules at November’s ministerial meeting, and Parker said the agency will get those under contract some time in 2023.
The Artemis 1 service module will end its mission about 40 minutes before splashdown when it separates from the crew capsule shortly before reentry. The service module will burn up in the atmosphere, with any surviving pieces falling into the Pacific Ocean west of Peru.
“It’s a little sad, but we’ve accomplished the mission,” Zimmerman said of the impending demise of the service module. “We are proud of all that has happened.”
“You cannot be sad when you accomplish your mission,” Deloo said. “Everything has a life. The end of the life is part of the life. As long as the life has been successful, this is a great success. So, I’m happy about it.”
NASA’s Orion spacecraft flew by the moon for a second and final time Dec. 5, performing a maneuver that sets up the spacecraft for a splashdown in the Pacific Ocean in six days. The Orion’s European Service Module fired its main engine for 3 minutes and 27 seconds starting at 11:43 a.m. Eastern. The maneuver, called the Return Powered Flyby, took place during a close approach to the moon that brought Orion within 130 kilometers of the lunar surface. NASA officials said at a later briefing that the maneuver, the largest and last major engine burn of the Artemis 1 mission, went as expected, putting the spacecraft on a trajectory that returns it to Earth for a Dec. 11 splashdown. That maneuver “is essentially our deorbit burn,” said Judd Frieling, flight director at NASA’s Johnson Space Center, at the briefing. “This sets us up for the landing trajectory that going to occur on Dec. 11.” With the flyby complete, NASA is moving ahead with preparations for splashdown. Mike Sarafin, NASA Artemis 1 mission manager, said the mission management team gave its approval to deploy recovery forces on Dec. 7. That includes a U.S. Navy ship, the USS Portland, that will host the recovery forces and bring the Orion spacecraft onboard to return to the port of San Diego, California. Melissa Jones, landing and recovery director for the mission at NASA, said the recovery team completed a three-day rehearsal for the recovery last week. “We are ready and honored, as an integrated team, to bring Orion home on the last leg of her journey,” she said. Orion, which launched nearly three weeks ago, continues to perform well with only minor problems. That includes continuing issues with latching current limiters in the spacecraft’s power distribution system. Four of those devices had switched off during a test, affecting power to six reaction control thrusters. Controllers were able to restore power to those thrusters.
A view of the Orion spacecraft, moon and Earth during the Dec. 5 return powered flyby of the moon by Orion. Credit: NASA
“What it appears is that they were commanded open, but there were no commands sent,” Debbie Korth, NASA Orion deputy program manager, said of the current limiters at the briefing. “We’re not exactly sure of the root cause yet.”
She said engineers are doing some testing of the power system in a ground-based lab, and will likely propose some tests to do later this week on the spacecraft ahead of the end of the mission. “We discard the service module, so we have a pretty limited window if there’s anything we want to do before that happens.”
She and other agency officials at the briefing downplayed the significance of it, noting there are redundant systems onboard. Had it taken place on a crewed mission, Frieling said, the astronauts would have been informed on their displays, but would not have noticed any other effects.
There was also a communications outage lasting four and a half hours on Dec. 3 that was caused by a hardware problem with a Deep Space Network (DSN) center in Goldstone, California. The outage would have been longer, Sarafin said, but the mission was able to negotiate with other missions using the DSN to get time on the network.
Praise from former agency leaders
The success of the mission to date won praise from two previous top NASA officials who see it as evidence that the overall Artemis effort is now on track after years of development delays.
“I feel really good about it,” former NASA Administrator Jim Bridenstine said at a SpaceNews event Dec. 5. “I think one of the biggest achievements is that there’s a lot of hardware here that has been under development for a long time. The Artemis program just gave all that hardware a mission, which is what we needed in order to get to where we are today.”
“I think it truly is a great thing to see this mission being so successful, as Jim said. A long time to get here, for sure,” said former NASA Deputy Administrator Lori Garver at the same event.
Bridenstine, who gave the Artemis program its name while in office during the Trump administration, credited the Biden administration for retaining it. “NASA has a long history of programs getting cancelled, and billions of dollars being wasted,” he said. “And in this case, they kept continuity of purpose and moved forward and I’m just very grateful for that.”
Garver, deputy administrator during the Obama administration, noted the program brought together hardware started in various administrations. “I think the timing was right and it was good to do,” she said. However, she expressed skepticism that the technical approach, including use of the Space Launch System, was the right one for the long term.
“I do not believe that the country can or should probably spend the amount of money we are on launch infrastructure over the longer term. I think that when we have private launch capabilities that rival this we should transition, and that will make me feel a lot better about the future and the future success of Artemis,” she said.
She said she had argued against SLS and Orion while at NASA, but lost that argument. “I was clear when I was at NASA that, once that decision had been made, our job was to make it the very best vehicle we could have.”
“You did not lose the argument,” Bridenstine said. “You got the argument started. It is still going forward and it’s transitioning how we do space.”
NASA’s Orion spacecraft entered a high-altitude orbit around the moon Nov. 25 in the latest major step in the Artemis 1 uncrewed test flight. The Orion spacecraft fired the main engine in its European Service Module at 4:52 p.m. Eastern for 88 seconds. The maneuver changed the velocity of the spacecraft by about 110 meters per second, placing the spacecraft into a distant retrograde orbit (DRO) around the moon. The use of DRO is unique to Artemis 1. The Artemis 2 mission will fly a free return trajectory around the moon, while Artemis 3 and later missions will go into a near-rectilinear halo orbit around the moon, which will also be used by the lunar Gateway. NASA chose DRO for this mission since it is a stable orbit that enables testing of the spacecraft without requiring much fuel to maintain the orbit. Orion, though, will not remain in DRO for long. The spacecraft will perform a maneuver Dec. 1 to depart DRO, heading back towards the moon. The spacecraft will conduct another burn during a lunar flyby Dec. 5 to put the spacecraft on track for a reentry Dec. 11, splashing down in the Pacific Ocean off the California coast. Since its Nov. 16 launch, the Artemis 1 mission has gone well, with only a few minor issues. “In terms of overall systems failures, we haven’t seen a single thing on the rocket or on the spacecraft that would have caused us to question our reliability or our redundancy,” Mike Sarafin, NASA Artemis 1 mission manager, said at the most recent briefing about the mission Nov. 21.
A view of Earth taken by a camera on an Orion solar array Nov. 24, a day before the spacecraft entered a distant retrograde orbit around the moon. Credit: NASA
At the time of that briefing, NASA said it was looking at two issues with the spacecraft, one involving the spacecraft’s star trackers and what Sarafin called “funny indications” on the power system on the service module, where one of eight units used to distribute power opened without being commanded to do so. Neither issue, he said, were “hard concerns or hard constraints” on the mission.
“We don’t fully understand what the system and the flight hardware is telling us, but we’ve got ample redundancy and we are recovering from these ‘funnies’ that we see,” he said.
On Nov. 23, NASA reported that it lost communications with Orion unexpectedly for 47 minutes starting at 1:09 a.m. Eastern. The loss of signal took place during one of a regular series of reconfigurations of the link between Orion and the Deep Space Network. It was unclear if the problem was with Orion or ground stations, and NASA has not provided an update on the issue since first reporting the glitch.
Sarafin also said at that Nov. 21 briefing that the Space Launch System rocket that launched Orion met or exceeded requirements. “The results were eye-watering,” he said. “Everything was either on predict or off by less than 1%.”
Engineers are also reviewing the status of the mobile launch platform, which sustained some damage from the launch, including having its elevator blast doors blown off and damage to the platform’s deck. “The mobile launcher has a little bit of damage to it, but it will be ready to fly the crewed launch on Artemis 2,” he said. That mission is scheduled to launch no earlier than late 2024.
An uncrewed test of NASA’s Space Launch System and Orion spacecraft moved a step closer to launch with the completion of a flight readiness review Aug. 22. NASA officials said late Aug. 22 that the review confirmed plans for a launch of the Artemis 1 mission from Kennedy Space Center’s Launch Complex 39B as soon as 8:33 a.m. Eastern Aug. 29, at the beginning of a two-hour window. A second two-hour window is available Sept. 2, and a 90-minute window Sept. 5. “We had no exceptions today. We actually had no actions coming out of the review and we had no dissenting opinions,” Jim Free, NASA associate administrator for exploration systems development, said at a briefing after the review. There is still some “open work” to do on the SLS and Orion spacecraft before launch, said Mike Sarafin, Artemis mission manager at NASA. Some of that is planned work to prepare the vehicles for launch, “largely things that we have a path to close before we go fly.” One issue that won’t be checked until the final stages of the countdown is a step called the “hydrogen kickstart” to thermally condition the engines. That could not be tested during the series of wet dress rehearsals of the vehicle in April and June because a leak in a hydrogen bleed line detected in the final rehearsal in June. Sarafin and Charlie Blackwell-Thompson, Artemis launch director, said there is a plan to test that step during a “quiescent” phase in the countdown a few hours before launch once the core stage’s liquid hydrogen tank is filled. “We believe that we have taken all the actions to correct that problem,” Blackwell-Thompson said, but won’t know for certain until the test at the pad.
The first launch of the Space Launch System remains on schedule for as soon as Aug. 29 after the Artemis 1 mission passed its flight readiness review Aug. 22. Credit: NASA/Joel Kowsky
“If we do not successfully demonstrate that,” Sarafin said, “we are not going to launch that day.”
A launch on Aug. 29 would start what is scheduled to be a 42-day mission for the Orion spacecraft. The SLS’s upper stage will place the spacecraft on a trajectory to the moon, called translunar injection (TLI), less than two hours after liftoff. Orion will fly by the moon five days later, maneuvering into a distant retrograde orbit around the moon. After spending two weeks in that orbit, the spacecraft will maneuver back to the moon, performing another powered flyby to bring it back to Earth, splashing down off coast of San Diego, California Oct. 10.
The six-week mission is a stress test of sorts of the spacecraft. Howard Hu, NASA Orion program manager, noted that Orion is designed to support a four-person crew for three weeks. “This mission allows us to push a lot of capability,” he said. “The long-class mission we’re talking about, 42 days, will allow us to stress a lot of systems.”
“Going 42 days puts a lot more stress on those systems, plus the environment it’s in — longer exposure to radiation, longer exposure to micrometeoroid hits — means we’re going to learn a lot from this test flight,” said Bob Cabana, NASA associate administrator. “We’re stressing it beyond what it is designed for and we’ll see what we learn.”
Cabana and others at the briefing emphasized that Artemis 1 was a test flight. “It’s not without risk,” he said. That includes scenarios, he said, where Orion is not able to complete the planned mission and returns early.
NASA, though, will push to at least send Orion towards the moon to enable the mission’s top objective, testing the spacecraft’s heat shield at lunar reentry velocities of about 40,000 kilometers per hour. That includes pressing ahead with TLI even if there are issues with the spacecraft, like a solar panel that doesn’t properly deploy immediately after launch.
“We have a lean-forward strategy to get our high-priority objective, which is to demonstrate the heat shield at lunar reentry conditions,” said Sarafin. “We’re going to press to the point of translunar injection unless we’re sure we’re going to lose the vehicle.”
“We would be go on this flight for conditions that we would normally be no-go for on a crewed flight in the interest of crew safety, because we want to buy down risk,” he added.
NASA's Pegasus barge arrived Sept. 27 at the agency's Kennedy Space Center in Florida with the core stage pathfinder for NASA's Space Launch System (SLS) rocket. The pathfinder will be used for lift and transport practice techniques inside Kennedy's Vehicle Assembly Building to prepare for the first lunar mission of SLS and NASA's Orion spacecraft, Artemis I. The core stage pathfinder is one of three pathfinder structures used by NASA to train lift crews on best practices for moving and handling the SLS rocket flight hardware. In addition to the core stage pathfinder, there is an RS-25 engine pathfinder and a solid rocket booster pathfinder. Designed as full-scale mockups of the flight hardware, the three SLS pathfinders each reflect the shape and size of the individual components of the rocket. The number of pathfinders for the rocket allow multiple teams to use the pathfinders for different operations and procedures at several processing locations. After teams at Kennedy practice with the core stage pathfinder in the VAB, NASA's Exploration Ground Systems will begin stacking operations with the booster pathfinder structures to simulate an aft booster assembly and bottom center segment stacking operation. All this practice prepares teams for the same upcoming tasks with the actual flight hardware. Engineers previously used the core stage pathfinder in August at NASA's Stennis Space Center near Bay St. Louis, Mississippi, where crews practiced similar lift and handling procedures into the B-2 Test Stand ahead of the Green Run test series for the core stage.
"After the pathfinder lift operations were complete, the unit was installed into the B-2 Test Stand at Stennis," said Barry Robinson, B-2 Test Stand core stage test project manager at Stennis. "Among other things, the exercise helped us identify minor facility modifications early enough to provide the time needed to make the corrections prior to the arrival of the core stage flight hardware."
Equipped with the largest rocket stage NASA has ever produced and the largest twin boosters ever built for flight, the SLS rocket for the Artemis missions will be the most powerful rocket in the world, enabling astronauts in Orion to travel to the Moon's south pole. The two massive propellant tanks in the rocket's 212-foot-tall core stage power the four RS-25 engines at the bottom of the rocket. On either side of the core stage are two, five-segment solid rocket boosters. Together, the engines and the boosters will produce a combined thrust of 8.8 million pounds during launch and flight. The rocket for Artemis I will tower at 322 feet.
"Practicing operations with pathfinders offers teams hands-on experience for managing and handling the immense structures before this one-of-a-kind flight hardware arrives," Robinson said.
Because the pathfinders replicate the flight hardware, the various pathfinders validate ground support equipment, and flight hardware access techniques as well as train handlers to transport the equipment on a variety of terrains with different vehicles, like the Pegasus barge and Kennedy's mobile launcher, and demonstrate how the equipment can be integrated within facilities.
"Experience is the best teacher," said Jim Bolton, EGS core stage operations manager. "Pathfinders allow crews to practice lifting, accessing and transporting techniques that we prefer not to do for the first time with the flight hardware. Practicing with a pathfinder reduces risk and builds confidence."
As crews at Kennedy use the SLS booster and core stage pathfinders for the same processes the actual flight hardware will undergo when processed at Kennedy for Artemis I, completed flight hardware for SLS and Orion will also be delivered.
"NASA's first Artemis mission flight hardware has progressed into final assembly and integration, moving well beyond the early design and manufacturing stages of development," said Mark Prill, SLS core stage pathfinder lead. "Flight hardware for both the SLS rocket and the Orion spacecraft will continue to be delivered to Kennedy as NASA prepares for the launch of Artemis I."
NASA is working to land the first woman and the next man on the Moon by 2024. SLS, along with Orion and the Gateway in orbit around the Moon, are NASA's backbone for deep space exploration. SLS is the only rocket that can send Orion, astronauts and supplies to the Moon on a single mission.
During Exploration Mission-1 (EM-1), an uncrewed Orion spacecraft will launch atop NASA's Space Launch System rocket and begin a three-week voyage in space, taking it about 40,000 miles beyond the Moon and back to Earth. On its return, the spacecraft's heat shield will need to withstand temperatures of nearing 5,000 degrees Fahrenheit during its fiery re-entry through the Earth's atmosphere before it splashes down in the Pacific Ocean. Technicians at NASA's Kennedy Space Center (KSC) in Florida recently secured the heat shield to the bottom of the crew module, using 68 bolts. Designed and manufactured by Orion prime contractor, Lockheed Martin, the heat shield is like an intricate puzzle with pieces that all have to fit together perfectly. Before the final installation, a fit check was performed to ensure all of the bolt fittings lined up. "Installation of the EM-1 crew module heat shield is a significant milestone representing the beginning of closing out the crew module assembly," said Jules Schneider, Lockheed Martin Orion senior manager for KSC Operations. "When the heat shield is installed, access to components becomes more difficult, and in some cases there is no more access. So by installing the heat shield you are declaring that a certain percentage of the spacecraft is finished."
Measuring 16.5 feet in diameter, Orion's new heat shield is the largest of its kind developed for missions that will carry astronauts. The heat shield base structure has a titanium truss covered with a composite substrate, or a skin composed of layers of carbon fiber material.
In a new process, several large blocks of an ablative material called Avcoat, licensed from Boston-based Textron Systems, were produced at Michoud Assembly Facility in New Orleans by Lockheed Martin. They were shipped to Kennedy, where Lockheed Martin technicians machined them into more than 180 unique blocks and bonded them to the heat shield's surface.
To fill tiny gaps between the blocks, the seams were filled with a mixture that over time will become solid. Technicians applied a coat of white epoxy paint to the heat shield's surface and then applied aluminized tape after the painted surface dried. The tape provides surface resistivity, and absorbs solar heat and infrared emissions.
"Witnessing assembly, test and installation of the EM-1 crew module heat shield brought an appreciation for its innovative design and assembly techniques," said Amy Marasia, the Crew Module Assembly operations lead in NASA's Orion Production Operations.
While Avcoat isn't new to spacecraft - it was used on the heat shields of Apollo and the Orion Exploration Flight Test-1 - the technique of using blocks instead of injecting the ablative material is proving to be a real production time-saver.
"A benefit of switching from the honeycomb system to the blocks is we now can make the Avcoat blocks at the same time that the Orion structure is being made, and when the module is ready we can secure the blocks, which saves time," said John Kowal, NASA Orion Thermal Protection System manager at Johnson Space Center in Houston.
"Before, with EFT-1, we had to wait for the carrier portion to be done, and then apply the Avcoat directly to the crew module."
During its first mission around the Moon, engineers will monitor how Orion's systems perform in the environment of deep space and its return to Earth. During re-entry the ablative material of the Avcoat blocks will burn away, essentially carrying the heat away from Orion because of the gases created during the ablative process.
Orion is the exploration spacecraft that will carry astronauts to deep-space destinations, including the Moon and on to Mars. Orion will be equipped with power, communications and life support systems to sustain space travelers during their long-duration missions and return them safely to Earth.
