Exploration Flight and Project Development Office Launch and Crewed Systems Office (MXS) Space Launch Systems WBS Payload Fairing Monthly Status Joe Roche April (March) 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 Spacecraft and Payload Office (SPIO) Payload Fairing GRC Project Manager: MXS / Joe Roche GRC Chief Engineer: Cameron Cunningham GRC Safety Mission Assurance Lead: Ron McClanahan NASA Customer: MSFC/SLS/SPIO Key Contractor(s): n/a MilestonesMCRSRR CkptSRRSDRPDRCDRDCREFT-1 LaunchEM-1 LaunchEM-2 Launch Program - Actual/Baseline3/11/1111/11/113/29/12 5/16/133/15/1510/1/1512/1/1512/1/178/1/21 SPIO – Actual/Baseline12/11/114/2 /128/15/125/15/132/15/15TBD

National Aeronautics and Space Administration Launch and Crewed Systems Office (MXS) WBS SPIO Payload Fairing 3 CostScheduleTechnicalManagement Current MonthGG G G Prior MonthGGGG Summary Status Issues & Help Needed:

National Aeronautics and Space Administration Launch and Crewed Systems Office (MXS) WBS SPIO Payload Fairing 4 Key Accomplishments: - The Payload Fairing team completed defining the potential tasks for the remainder of FY13 and FY14 on March 4 th. Focus for FY13 was directed toward answering the major questions for the use of an existing 5m fairing on the SLS vehicle, specifically the separation and acoustic issues. The FY14 effort focus would be on aligning the project toward an SRR by ensuring that major risks have been identified and technically assessed and viable mitigation strategies have been defined. The FY14 effort will also identify and quantify significant opportunities that could be realized in the manufacturing and integration/operation of the fairing. A summary of the tasks were delivered to SPIO management on March 7 th for review and feedback. Pending SPIO task approval, a new schedule will be developed for base lining. - Completed the draft documentation of the current Composite Fairing configuration in SLS-SPIO-RPT-005 “Payload Fairing Design Description” with all comments and suggestions from the GRC Chief Engineer review incorporated on March 5 th. This document provides a reference to the baseline SPIO Payload Fairing and describes the overall architecture, sub-system concepts, and operational characteristics envisioned to enable cargo launch capabilities for space exploration and science missions. This reference will be used to compare all alternative concepts and subsystem options. The basic configuration definition is necessary to provide the reference for the development of functional and performance design requirements as well as the identification of various internal and external interfaces of the element and cost estimation. The document has been released to the Fairing WBS leads for review and comment. - A risk assessment workshop was conducted on March 7 th to identify and capture the risks for the use of an existing 5m fairing on SLS and the development of a new 8.4m fairing. Risks are being consolidated and reviewed with eventual input into the Risk Management Implementation Tool (RMIT) database for evaluation and tracking.

National Aeronautics and Space Administration Launch and Crewed Systems Office (MXS) WBS SPIO Payload Fairing 5 Key Accomplishments: - A meeting was held with Mr. Bill Hooper, Director of Technology Development at ATK, Mr. Charles Bown, NASA Program Development, Mr. Richard Rynders, Mr. Andy Jackson, Launch Structure, Mr. Marcel Bluth Engineering Technology Manager, Ms. Patricia May, Project Manager, Mr. David Beaman, SPIO Project Manager, and Mr. Joe Roche, Payload Fairing Project Manager on March 13 th at ATK, Utah. The meeting was to assess ATK potential capabilities and manufacturing approaches used on the A350 composite aircraft. An internal effort to investigate the use of the hat stiffened composite construction is being performed with Ruag to assess the benefits of the concept and potential savings in cost and mass. - Completed the initial separation simulation for the Boeing Delta IV 5.1 meter diameter composite fairing with the SLS vehicle on March 14 th. The properties of the fairing for the actual fiber and resin systems in the fabric form used by the manufacturer were incorporated to obtain the stiffness of the structure. The separation simulation analysis was performed to determine if the fairing is able to safely separate from the larger diameter 8.4m SLS vehicle. The simulation results are being post processed and a summary report is being assembled. - A presentation was given to Mr. Dan Dumbacher, Deputy Associate Administrator for Exploration Systems and Development, Mr. Jason Jenkins, and Steve Creech by Mr. David Beaman, SPIO Project Manager and Mr. Joe Roche, Payload Fairing Project Manager on March 11 th. The presentation was a summary of the evaluation data from the Payload Fairing and Adapter Request for Information (RFI) responses. 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 appreciation for the team effort and quality of the package.

National Aeronautics and Space Administration Launch and Crewed Systems Office (MXS) WBS SPIO Payload Fairing 6 Key Accomplishments: - Completed the baseline separation simulation of the Boeing Delta IV composite fairing on March 28th. The model included the as-built material systems and architecture to capture the correct mass and stiffness of the fairing petals and used the heritage separation system as the forcing function. The simulation showed adequate clearance is obtained with the use of the auxiliary separation springs at the base of the fairing. Significant re- contact was indicated when the springs were not employed in the separation event. Further investigation will be conducted to determine the acceleration limit that still clears the Launch Vehicle Spacecraft Adapter (LVSA) and the 8.4m diameter core stage. Sensitivity to other factors such as Angle of Attack (AoA) and Thrust Force dispersions will also be quantified. - The first SpaceX Fairing Deployment test is planned for March 29th at Plum Brook’s Space Power Facility (SPF). The test series will cover a number of separation tests to qualify the unique non-pyrotechnic cold gas separation system under nominal and off-nominal conditions. The planned Electro Magnetic Interference (EMI) qualification test series has been deferred due to inadequate seals installed in the fairing that will affect the test data. An Acoustic qualification test series in the Reverberant Acoustic Test Facility (RATF) located adjacent to the vacuum dome at SPF is scheduled to start after completion of the Deployment test, approximately mid-May..

National Aeronautics and Space Administration Launch and Crewed Systems Office (MXS) WBS SPIO Payload Fairing 7 30/60/90 day Look-ahead  30 day (April): 5m Fairing: Complete Structural Assessment 5m Fairing: Update Risk Database & Matrix Add secondary tasks to WBS and resource load FY13 Schedule  60 day (May): 5m Fairing: Complete Analysis of Existing Fairings & Separation Analysis Define Cost & Mitigation approaches for 5m Fairing risks assessments 8.4m Fairing: Complete Construction Models & Concept Description Draft Doc PDR kick off  90 day (June): Complete 5m Fairing Assessment Report Draft Complete 8.4m Structural Assessment

National Aeronautics and Space Administration Launch and Crewed Systems Office (MXS) WBS SPIO Payload Fairing 8 Project is less than 1 month behind planProject is less than 2 months behind planProject is greater than 2 months behind plan Schedule Color Key Milestone Summary Milestones (FY13)BaselineProjectedActualSchedule Variance Program – SRR CheckpointNov 11Nov 12 SPIO – SRR/SDR CheckpointDec 13Dec 9 Program – SRR / SDRMar 12Mar 29 SPIO – SRR (kick off)April 2 SPIO – SDR (kick off)AugustAugust 29 SPIO – SDR (board)OctoberOctober 17 SPIO PDR Kick-offMay 15 SPIO BoardJune 27