1. Ares I-X INDUSTRY DAY Scott Graham William Foster Monica Hoffmann
National Aeronautics and Space Administration
Ares I-X INDUSTRY DAY
Scott Graham
William Foster
Monica Hoffmann
Timothy Gaydos
14 November 2007

2. AGENDA 8AM Badging and Manufacturing Facilities Tour Sign Up
8:30AM Welcome
8:35AM Ares Program Overview
8:45 AM Ares 1-X Program Overview
9AM Ares1-X Statement of Work
9:50AM Quality Assurance Plan
10AM Open Forum Questions and Answers
10:30AM Tours of Ares1-X Manufacturing Facilities
11:30AM- 1PM – LUNCH - Break Independently for Lunch
1PM Continue One on One Private Conversations as needed
(20 minutes each)
National Aeronautics and Space Administration

3. Ares Program Overview Scott Graham November 14, 2007
National Aeronautics and Space Administration
Scott Graham
November 14, 2007

4. The Vision for Space Exploration
Complete the International Space Station.
Safely fly the Space Shuttle until 2010.
Develop and fly the Crew Exploration Vehicle no later than 2014 (goal of 2012).
Return to the Moon no later than 2020.
Extend human presence across the solar system and beyond.
Implement a sustained and affordable human and robotic program.
Develop supporting innovative technologies, knowledge, and infrastructures.
Promote international and commercial participation in exploration.
“The next steps in returning to the Moon and moving onward to Mars, the near-Earth asteroids, and beyond, are crucial in deciding the course of future space exploration. We must understand that these steps are incremental, cumulative, and – incredibly powerful in their
ultimate effect.”
– NASA Administrator Michael Griffin October 24, 2006
NASA’s call to action was the Vision for Space Exploration, announced in The primary goals of the Vision are to finish the work NASA began on the International Space Station, retire the Space Shuttle, and build the new spacecraft needed to return people to the Moon and go on to Mars. The importance of the Vision is that it commits NASA and the nation to an agenda of exploration. Alongside this effort, we will continue developing a vigorous program of robotic exploration and technological development to meet the challenges ahead.
National Aeronautics and Space Administration

5. Our Exploration Fleet Earth Departure Stage Orion Crew Exploration
Vehicle
Ares V
Cargo Launch Vehicle
The journeys to the Moon and Mars will require a variety of vehicles, including the Ares I Crew Launch Vehicle, the Ares V Cargo Launch Vehicle, the Orion Crew Exploration Vehicle, and the Lunar Surface Access Module (LSAM). The architecture for lunar missions will use two launches, with the crew going up on one vehicle, and the lunar lander and the Earth Departure Stage going up on another.
The crew launch vehicle has been named Ares I—the ancient Greek name for Mars—anticipating one of its future destinations, while the cargo launch vehicle has been named Ares V. The “I” and “V” designations pay homage to the Apollo Saturn I and Saturn V launch vehicles.
Ares I is a “single stick” vehicle stack designed to carry the human crew into orbit. It is being designed to carry crew or cargo to the International Space Station (ISS) and to carry the crew to rendezvous with the Ares V Earth Departure Stage and LSAM.
The Ares V Cargo Launch Vehicle carries the LSAM into orbit and provides the propulsion to push Orion and LSAM toward the Moon.
The Orion Crew Exploration Vehicle carries the crew into orbit, where it docks with the LSAM before heading for the Moon. It is the same shape as the Apollo capsule, but has enough space to carry up to six astronauts for an ISS mission or four astronauts to the Moon. Along with more advanced electronics, Orion also has more than two-and-a-half times the interior space of the original Apollo Command Module. When Orion and LSAM reach the Moon, Orion remains in orbit on “automatic pilot” while the crew descends to the surface in the LSAM.
The LSAM will take the four crew members to the surface, where it will serve as the crew’s habitat for up to a week on a lunar sortie mission. Once the mission is over, the upper portion of the LSAM launches the crew into lunar orbit and then docks with Orion. Once crew and cargo have been transferred back to the Orion, the LSAM is discarded and allowed to crash onto the Moon’s surface while the crew returns to Earth in Orion.
Lunar Lander
Ares I
Crew Launch Vehicle
ELO Ambassador Briefing – 5
National Aeronautics and Space Administration

6. Building on a Foundation of Proven Technologies - Launch Vehicle Comparisons -
Crew
Lunar
Lander
Lander
Orion CEV
Earth Departure
Stage (EDS) (1 J–2X)
499k lb LOx/LH2
S–IVB
(1 J–2 engine)
240k lb LOx/LH2
Upper Stage
(1 J–2X)
280k lb LOx/LH2
S–II
(5 J–2 engines)
1M lb LOx/LH2
5-Segment Reusable Solid Rocket Booster (RSRB)
Core Stage
(5 RS–68 Engines)
3.1M lb LOx/LH2
In order to reach the Moon and Mars within our planned timeline and also within our allowable budget, NASA is building upon the best of our known space transportation systems. The Ares I and Ares V launch vehicles use many technologies drawn from Apollo and the Space Shuttle. The five-segment RSRBs are bigger, more powerful versions of the four-segment RSRBs that the Shuttle uses today. While larger, much of the hardware on these engines will be identical. This is a cost and time savings, as we can use existing manufacturing techniques and personnel to build them. Proven hardware designs also increase vehicle reliability and safety.
The J-2 engine was used for the upper stages of the Saturn V moon rocket and has undergone continual improvements over the years—most recently, the turbopumps for a version called the J-2S were used to test a linear aerospike engine on the X-33 program. Thanks to more advanced components and more powerful turbomachinery, the J-2X will have 60,000 pounds more thrust than the original J-2. And, again, because it is a proven, known design, the J-2X is less expensive than if we tried to modify the Space Shuttle Main Engine or build a new engine altogether.
S–IC
(5 F–1 engines)
3.9M lb LOx/RP
Two 5-Segment
RSRBs
Space Shuttle
Ares I
Ares V
Saturn V
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7. Ares I-X: The First Test Flight (April 2009)
Thrust < 40K lbs
Separation begins
Launch
Booster
Recovery
Upper Stage
and CEV/LAS
Disposal
Sep + 20 secs
Chute deployment
Sep + 10 secs
Frustum/Interstage separation
USS/CM/LAS
data downlink
National Aeronautics and Space Administration

8. Ares I-X Upper Stage Simulator Overview
National Aeronautics and Space Administration
Ares I-X Upper Stage Simulator Overview
William Foster
Industry Day
November 14, 2007

9. Purpose & Content Purpose: Content:
Introduce the Ares I-X Flight Test Project and GRC’s Upper Stage Simulator (USS) Integrated Product Team (IPT).
Content:
USS IPT Organization
Ares I-X Flight Test Overview
USS Top Level Requirements
Design Concept
Operations Concept
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10. Safety & Mission Assurance (S&MA) Management Office (MMO)
Ares I-X Organization
Safety & Mission Assurance (S&MA)
Ares I-X Mission
Management Office (MMO)
Chief Engineers
Joe Brunty/MSFC
Dan Mullane/MSFC
Bob Ess
Mission Manager
K. Robinson
Project Integration
Steve Sullivan/KSC
Steve Davis
Deputy, MSFC
JSC/TBD
Budget Analyst
Carol Scott
Deputy, KSC
Support Staff
Systems Engineering
& Integration (SE&I)
Marshall Smith
SE&I Chief
M. Smith/LaRC
Chief
K. Detweiler/LaRC
LSE
W. Pennington/LaRC
Deputy Chief
S. Richards/MSFC
Deputy LSE
Integrated Product Teams (IPTs)
Ground
Operations
(GO)
First Stage
Avionics
CM/LAS
Simulator
Scott Thurston/KSC
Chris Calfee/MSFC
Kevin Flynn/MSFC
Brian Beaton/LaRC
Ground
Systems
(GS)
Upper Stage
Simulator
(USS)
Roll Control
System
(RoCS)
Vince Bilardo/GRC
Ron Unger/MSFC
Jon Cowart/KSC
National Aeronautics and Space Administration

11. Launch Systems Projects Office Glenn Research Center
Chief: S. Graham Deputy Chief: J. Koudelka
MSA: J. Van Horn
Admin Support: C Schilens
Flight & Integrated Test: MSFC
Safety & Mission Assurance (S&MA)
J. Rusick
- Test Vehicle Integration -LaRC
Struct, Envir & Vibration Test
Lead: M. Tuma
Program Planning & Control
Manager: R. Speth
Project Control Specialist: Vacant
Test Vehicle Integration
Deputy: P. Bartolotta
Analyst: T. Halstead
RAMO: C. Stofka
Vehicle Integration
Lead: G. Sadler
Upper Stage
Manager: D. Hoffman
Upper Stage Engine
Manager: C. Meyer
Deputy: J. Rybak
Ares I-1 GRC Elements
Manager: V. Bilardo
US Test Article Lead: W. Foster
Interstage Element Lead: M. Hoffmann
Ground Processing Lead: J. Lekan
Chief Engineer: C. Cunningham
Integrated Upper Stage: tbd
Kurt Hack, IDA
T. Krivanek, M. McNelis, D.K. Le, J. Cruz / IV&V
CEV SA/SM Test Article Lead: F. Elliott
A. Narvaez-Legeza, Lead Engr.
S. Numbers, PA Lead
Avionics
Lead: A. Jankovsky
Thrust Vector Control
Lead: D. Frate
Deputy: N. Pham
Structures & Thermal
Lead: C. Tolbert
Direct
A. Baez, EPS
J. Thomas, DFI
G. Hunter, Sensors
R. Tornabene, IPT Lead
C. Ensworth
B. Frankenfield
Matrix
National Aeronautics and Space Administration

12. AIX USS IPT Organization
08 Aug 07

13. Ares I-1 Flight Test Profile
Thrust < 40K lbs
Separation begins
Launch
Booster
Recovery
Upper Stage
and CEV/LAS
Disposal
Sep + 20 secs
Chute deployment
Sep + 10 secs
Frustum/Interstage separation
USS/CM/LAS
data downlink
National Aeronautics and Space Administration

14. Flight Test Plan USS Constraints
Item
USS Requirements and Constraints 1
USS shall be designed to allow all assembly and checkout with limited, internal access from Interstage area; No other access above Interstage will be provided. 2
Development Flight Instrumentation (DFI) will be installed and tested at GRC prior to shipping. Final integrated instrumentation checks will be performed at KSC with EGSE provided by FTV. 3
USS shall not be recovered and will free fall into the ocean. 4
USS shall simulate the Ares I Upper Stage OML and will have sufficient mass property (total mass, CG, and inertias) characteristics to meet primary objectives. 5
USS Flight Termination System shall not be required. 6
Unique GSE for USS transportation, assembly, and test will be fabricated at GRC. 7
Processing of USS hardware will be in accordance with Appendix E, Problem Reporting and Work Control Plan.
National Aeronautics and Space Administration

15. Spacecraft Adapter and Service Module Simulators
USS Architecture
USS Hardware
Interstage (IS) Simulator
Internal Access Service Panel
Integration of other Elements:
Roll Control System (RoCS)
Separation event diagnostics and instrumentation system
Upper Stage (US) Simulator
Spacecraft Adapter (SA) Simulator
Service Module (SM) Simulator
Integration of avionics/DFI along the length of the USS
USS External Interfaces
First Stage (FS)
RoCS
Crew Module/Launch Abort System (CM/LAS)
Avionics
Ground Systems (GS)
Simulated fifth segment
CM/LAS
Simulator
Four-segment motor
Upper Stage Simulator FS
Frustum
Avionics
(internal)
Forward Skirts
Spacecraft Adapter and Service Module Simulators
Upper Stage
RoCS
USS to RoCS Interface
USS to CM\LAS Interface
USS to FS Interface
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16. USS Internal Access Concept [USS-012, -013, -023, -024, -095, -103, -108, -110]
Provides human access from the FS Frustum to the CM/LAS via the Upper Stage Access Arm at the KSC launch pad 39B and VAB platform E scaffolding
Door in the IS-1
Internal access platforms and ladders
Provides ECS ductwork to maintain a safe work temp., air flow and controlled humidity
Allows for installation and assembly of hardware
Ladders are staggered 90 degrees between platforms
Internal access door
Ballast platform
Access platforms with railings
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17. USS ECS & Ascent Venting [USS-108, -023, -024, & USS-014]
14” ECS Duct
Avionics ducting
not shown
Typical Segment
Typical Stack
8” Ascent Vents
Backflow device
not shown
8” Ascent Vents
Backflow device
not shown
US-1
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18. USS Adjustable Mass Ballast [USS-017, -075, -123]
USS is a mass simulator
Provides majority of adjustable ballast for FTV’s mass, CG, moment of inertia distribution
2” Ballast Plates are ~ 7,500 lbs each
US-1 ~ 17 plates +/- 2 plates
US-7 ~ 5 plates +/- 2 plates
Total adjustable ballast ~ TBD lbs
Upper adjustable ballast (US–7)
Lower adjustable ballast (US–1)
National Aeronautics and Space Administration

19. NOTE: Under revision based on the DFI
DFI/OFI in USS [USS-057]
1 – Calorimeter; 31 – Pressure Transducers;
1 – Thermocouple; 3 – Accelerometers (HF);
8 – Accelerometers (LF); 8 – Strain Gauges SM
Types of DFI Sensors:
Calorimeter Medtherm 20850
Pressure Transducer Kulite XTL-190
Thermocouple Type K
Strain Gage (Uniaxial) Vishay TBD or Equal
Strain Gage (Triaxial) Vishay TBD or Equal
Gas Temperature Probe Medtherm 10561K
Accelerometer (LF) PCB 3741D4HB
Accelerometer (HF) Endevco 7251
Accelerometer (Shock) PCB 350C31
Video Cameras TBD
DFI Avionics Boxes:
MDAU (Master Data Acquisition Unit)
RDAU (Remote Data Acquisition Unit)
Honeywell SIGI (Space Integrated GPS/INS)
Systron-Donner MotionPaks (Qty = 2)
OFI Avionics Boxes:
FTINU – Fault Tolerant Inertial Navigation Unit
RRGU – Redundant Rate Gyro Unit
18 – Pressure Transducers; 10 – Strain Gauges; 8 – Accelerometer (HF); 4 – Triaxial Strain Gauges; 1 – Microphone SA
1 – RRGU; 2- MDAUs 1 – Video Camera; 1 – SIGI ;
11 – Pressure Transducers; 1 – Calorimeter; 1 – Thermocouple; 3 – Accelerometers (HF)
US-7
US-6
4 – Strain Gauges;
12 – Pressure Transducers
US-5
NONE
US-4
4 – Strain Gauges;
4 – Pressure Transducers
US-3
2 – Pressure Transducers
2 – Calorimeter; 2 – Thermocouples;
8 – Pressure Transducers; 4 – Strain Gauges
US-2
1 – FTINU; 6 – Pressure Transducers; 2 – Calorimeters; 2 – Thermocouples;
3 – Accelerometers (Shock)
US-1
IS-2,
IS-1
NOTE: Under revision based on the DFI
List Version 3.05
3 – Video Cameras; 28 – Pressure Transducers; 13 – Calorimeters; 18 – Thermocouples;
11 – Accelerometers (LF); 12 – Triaxial Strain Gauges; 3 – Accelerometers (Shock)
National Aeronautics and Space Administration

20. US-6 Common Segment Description
Design is identical to CDR Charge 1 Segments (US-2,3,4,5)
Steel Grade A70, ½” thick skin, 18’ dia.
Avionics located in segment: Ext. Video Camera (1)
ECS
National Aeronautics and Space Administration

21. US-7 Ballast Segment - Description
Provides adjustable ballast for FTV’s mass, CG, moment of inertia distribution
2” Ballast Plates are ~ 7,500 lbs each
US-7 ~ 5 plates (37,677 lbs) +/- 2 plates :
Avionics located in US-7 includes: RRGU (1), MDAUs (2) , Ext. Video Camera (1)
Bolt On
Lifting Lug
ECS
US-7- Ballast Segment Mass Properties
Primary Structure: ,662.00
Ballast Support Structure: ,295.90
Ballast Plates (5): ,677.00
Ballast Fasteners:
Super Lifting Lug (4): ,469.36
Top Ladder (2):
Bottom Ladder (2):
Up Alignment Tang (4):
Down Alignment Tang (4):
External Flange Ring (1):
External Flange Ring (1):
OML UHF Antenna (2):
OML Camera (2):
ECS Duct:
Sub Total: ,719.81
Ballast Can
Assembly
Platform
National Aeronautics and Space Administration

22. Spacecraft Adapter Segment Description
ECS
Spacecraft Adapter Segment
Conical Shape Segment-Provides the diameter reduction transition from 18 ft. (216.5”) to 16.5 ft (198 “).
Steel Grade A70, ½” thick skin
Provides similar internal access, ECS design as common segments
Internal Access
Bolt On
Lifting Lug
Spacecraft Adapter Mass Properties
Primary Structure: ,012.76
Walkway: ,145.11
Platform Hangers:
Lifting Lug (4):
Up Alignment Tang (4):
Down Alignment Tang:
ECS Duct:
Sub Total: ,631.26
National Aeronautics and Space Administration

23. Service Module Segment Description
ECS
Flange I/F
With CM/LAS
Service Module Segment
SM Simulator connects to the CM Separation Ring Simulator.
NASA LaRC is responsible for the CM/LAS simulator.
Design similar to common segment; except reduced diameter from 18 ft. (216.5”) to 16.5 ft (198 “)
Provides Internal Access to allow access to CM instrumentation.
Segment interfaces with CM/LAS. This interface includes mechanical bolting of the structural flanges, avionics and environmental interfaces.
Segment Upper Flange is machined to meet the flatness requirements for CM/LAS interface.
Gussets
Bolt On
Lifting Lugs
Internal Access
Service Module Mass Properties
Primary Structure: ,259.76
Walkway: ,048.54
OML Thruster 2 Pack (2):
OML Thruster 6 Pack (2):
Up Alignment Tang (4):
Down Alignment Tang (4):
Lifting Lug (4):
ECS:
Sub Total: ,585.75
National Aeronautics and Space Administration

24. Interstage 1 Segment Internal Access Entry RoCS interface
Services USS and CM/LAS
ECS services
1st stage entry
RoCS interface
Interface to 1st Stage
Last segment to be built
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25. USS Element Concept of Operations Overview
-USS Segments to be transported
On the Delta Mariner Vessel
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26. USS IPT Concept of Operations Processing Flow
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27. USS IPT Concept of Operations Super Segments at GRC
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28. USS IPT Concept of Operations Super Segments at KSC
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29. USS Element Concept of Operations Flow Post Manufacturing at GRC
National Aeronautics and Space Administration