exploration flight and project development office launch and crewed systems office (mxs) space...

Exploration Flight and Project Development OfficeLaunch and Crewed Systems Office (MXS)Space Launch SystemsWBS 585777.08.50 Payload FairingMonthly Status

Joe RocheMarch (February) 2013

2

Project Mission Statement:• Develop and produce cargo payload fairings for

the initial and block 1 SLS launch vehicles

GRC Scope:• Project leadership of a multi center team• SE&I Lead• Structures Lead• Payload Environmental Control Lead• Mechanical Systems Lead• Ground Systems Lead• System Integration & Test Lead (includes major

qualification testing)

Project Life Cycle Schedule

Launch and Crewed Systems Office (MXS)WBS 585777.08.50 Spacecraft and Payload Office (SPIO) Payload Fairing

GRC Project Manager: MXS / Gerry Sadler

GRC Chief Engineer: Damian Ludwiczak

GRC Safety Mission Assurance Lead: QE/Scott Numbers

NASA Customer: MSFC/SLS/SPIO

Key Contractor(s): n/a

Milestones MCR SRR Ckpt SRR SDR PDR CDR DCREM-1

LaunchEM-2

LaunchEM-3

LaunchEM-4

LaunchProgram - Actual/Baseline 3/11 11/11 3/29 3/29 3/15 3/16 10/15 12/15 8/15 8/15 8/15

SPIO – Actual/Baseline 12/11 4/2 August 1/13 1/15 8/16

3National Aeronautics and Space Administration

Launch and Crewed Systems Office (MXS)WBS 585777.08.50.66.22.10 SPIO Payload Fairing

Cost Schedule Technical Management

Current Month G G G G

Prior Month G G G G

• Summary Status

• Issues & Help Needed:


Launch and Crewed Systems Office (MXS) WBS 585777.08.50.66.22.10 SPIO Payload Fairing

Key Accomplishments:– Continuing independent sizing of the Boeing Delta IV 5.1 meter diameter composite fairing. The Finite Element

Model (FEM) was completed on January 22nd. Aerodynamic loads are being mapped to the model and structural sizing will be performed using the actual material system as soon as properties are obtained. This analysis will be used to compare and validate the current sizing methodology and analytical processes with the received Boeing Request for Information (RFI) submitted values for the 5.1 meter fairing.

– A meeting was held between the Boeing Company and the Payload Fairing team at GRC on January 24 th. Boeing representatives included Mr. Mark Cleveland, Mr. Bob Dalee, Mr. David Frost, Mr. Thomas Fung, Mr. Mike Shaw and Mr. Bryan Willhoite. The meeting focused on addressing questions identified from the Boeing RFI response and gaining additional insight into the design, qualification, assembly, and operations aspects of the Boeing Delta II, IV and Sea Launch fairings.

– The Payload Fairing team completed evaluating the Payload Fairing and Adapter RFI Section 5.0, “Development of an 8.4m Meter Fairing” (new 8.4m diameter fairing design) on January 25 th. Results of the evaluation are being consolidated and summary charts are being assembled.

– Mr. Thomas Fung, Program Manager, Delta IV Payload Fairing, presented the Delta IV 5.1 meter metallic payload fairing overview and design to the GRC Fairing team on January 25 th. The Delta IV metallic payload fairing was designed and developed by Boeing under the Titan IV program and has flown successfully on 33 flights. Mr. David Frost, Director, Sea Launch Payload Accommodations Hardware, presented the Sea Launch 4 meter composite payload fairing and lessons from the fabrication of an Out-of-Autoclave 4 meter fairing. The Sea Launch 4 meter composite payload fairing was designed and developed by Boeing using the latest composite technology and has flown successfully on 33 flights.



Key Accomplishments: A briefing was presented on the “Payload Fairing 5m Class Separation Assessment Process” to Mr. Rene

Ortega and the SPIO Engineering Review Board (ERB) on February 5th. The purpose of the briefing was to inform the board of the methodology and tools used to produce a fairing separation simulation. This analysis will be used to determine if the existing 5m class fairings can clear the 8.4m SLS vehicle while using qualified heritage separation systems. It will also determine what the limitations for separation are as far as vehicle axial acceleration, and additional acoustic treatment (mass) limits. A secondary objective was to validate the Fairing team’s structural modeling methodology and tools by demonstrating sizing, design criteria, mass factors and Mass Growth Assumptions (MGA) are in line with existing fairing designs flown

. The Fairing team completed assembling a summary presentation of evaluation data from the Payload Fairing

and Adapter Request for Information (RFI) responses on February 6th. The summary includes results for Section 3.0, “Adaption of Existing Available Payload Fairings” (potential existing 5m class fairings) and Section 5.0, “Development of an 8.4m Meter Fairing” (new 8.4m diameter fairing design). Data on the MSFC evaluation of Section 4.0, “Adaption of Existing Available Payload Adapters” is due on February 8th to complete the package. A GRC management review is scheduled for February 15th.

A meeting was held with Lockheed Martin representatives Mr. Gary Howard, Program Manager, and Mr. Mike Gnau, Business Development Manager at GRC on February 8th. A list of questions from the Payload Fairing team on the Lockheed Martin-Ruag Space RFI response was reviewed and programmatic questions were answered. Lockheed Martin will be meeting with Ruag on February 11th to address many of the technical questions and another meeting between the Fairing team and Lockheed will be schedule to discuss all of the questions.



Key Accomplishments:– The bottoms up 119’ Composite Payload Fairing cost estimate was presented to Mr. David Beaman, SPIO Project

Manager, Ms. Lori Mullins, SPIO Technical Assistant, Mr. Rene Ortega, SPIO Chief Engineer, and Mr. Jim Lomas, Spacecraft and Payload Accommodations Systems lead, on February 13th. The cost estimate showed a significant cost savings over the current baseline. The estimate was also corroborated with recently received Payload Fairing Request for Information (RFI) responses from industry.

– Equivalent material properties for the Ruag Atlas V fairing were derived on February 13th. Requested actual properties were not available due to proprietary issues. The estimated properties were produced from the basic T300 fiber and MTM45 matrix properties using the pcGina micro-mechanics program with adjustments for the fiber volume to simulate the resin rich fabric manufacturing process. Fairing resizing is in process and updated weights and stiffness will be provided for the separation simulation. Adjustments are also being incorporated into the separation model to account for the proposed stretched ICPS Hydrogen tank that will provide additional clearance for the fairing due to the added 5m diameter tank length.

– The Payload Fairing team presented a summary of the evaluation data from the Payload Fairing and Adapter RFI responses results to GRC Management on February 15th. The summary includes results for Section 3.0, “Adaption of Existing Available Payload Fairings” (potential existing 5m class fairings) and Section 5.0, “Development of an 8.4m Meter Fairing” (new 8.4m diameter fairing design). Data on the MSFC evaluation of Section 4.0, “Adaption of Existing Available Payload Adapters” was not reviewed. Concurrence was received from GRC Management with a few minor suggested modifications. Revisions will be incorporated and the summary is scheduled to be presented, with the 4.0 Payload Adapter information included, to the SPIO management on February 20th.



Key Accomplishments:- Completed the preliminary sizing for the metallic Delta IV-43M fairing on February 19 th. The model includes the

HyperSizer default isogrid construction rotated by 90 degrees for the barrel and the two nose pieces, with the nose tip modeled as a solid plate. The fairing sizing with updated weights for the non-structural mass, and stiffness will be provided for the separation simulation to assess the feasibility of the tri-sector fairing for a SLS mission.

- The Payload Fairing team presented a summary of the evaluation data from the Payload Fairing and Adapter Request for Information (RFI) responses to Mr. David Beaman, SPIO Project Manager, Mr. Rene Ortega, SPIO Chief Engineer, and Mr. Jim Lomas, Spacecraft and Payload Accommodations Systems lead, on February 20 th at MSFC. The summary included results for Section 3.0, “Adaption of Existing Available Payload Fairings” (potential existing 5m class fairings), the MSFC evaluation of Section 4.0, “Adaption of Existing Available Payload Adapters”, and Section 5.0, “Development of an 8.4m Meter Fairing” (new 8.4m diameter fairing design). The review was well received with concurrence on the results with a few minor suggested modifications to be incorporated before the package is to be presented to Mr. Dan Dumbacher, Deputy Associate Administrator for Exploration Systems and Development.



Reporting Monthly Priorities • Lockheed Martin meeting with Fairing team (responses to RFI

questions), TBD.

• Proposed Fairing FY’14 tasks to SPIO, March 7th.

30/60/90 day look ahead:• Baseline Fairing configuration briefing at PDR Kick-off, May 15th.

National Aeronautics and Space Administration

AccomplishmentsFebruary

9


Next 2 Months Travel (Location/Dates/Purpose/)- Funded and Unfunded

Location From To Funded Purpose

JPL 1-28 1-30 y Explore sls mission possibility

National Aeronautics and Space Administration


10

Project is less than 1 month behind plan Project is less than 2 months behind plan Project is greater than 2 months behind plan

Schedule Color Key

Milestone SummaryMilestones (FY13) Baseline Projected Actual Schedule Variance

Program – SRR Checkpoint Nov 11 Nov 12

SPIO – SRR/SDR Checkpoint Dec 13 Dec 9

Program – SRR / SDR Mar 12 Mar 29

SPIO – SRR (kick off) April 2 April 2

SPIO – SDR (kick off) August August 29

SPIO – SDR (board) October October 17

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