STC Making a Splash!
NASA has been preparing to go back to deep space with the development of the Orion Crew Module, which has gone through changes since the Constellation Program was cancelled. The Orion Crew Module was essentially retained from that program and STC has continued to support various projects associated with Orion. STC has built or been a part of three crew module flight test articles, which have included ARES-1X, Pad Abort 1, and Max Launch Abort System (MLAS). But what goes up must come down, and work has been ongoing with drop tests at Langley Research Center (LaRC) in preparation for water landings. STC has been instrumental in the fabrication of the Boilerplate Test Article (BTA) (pictured above), which has gone through a series of water impact tests at the Langley Hydro Impact Basin. Since that series of tests, the Lockheed Martin built Ground Test Article (GTA) has been delivered to LaRC to prepare it for its own series of water impact tests. Lockheed Martin is the prime contractor for the crew modules that NASA will be flying. STC has supported modifications to the GTA and participated in critical lifts to mate and de-mate the GTA with the heatshield. STC has been supporting this effort, led by Eric May. Eric and Matt Stearman spent several months working the SPLASH project. Since then, a number of STC staff have supported the project, including Max Reid, Bill Weigel, Mike Barney, Jeri Carter, Cathy Kern, Rick Thomas, Ron Tucker, Brenda Adams, Bill Girard, Danny Lovaglio, and Tom Hall. This support has been comprehensive, covering mechanical support, machining, instrumentation, laser tracking, and electronics. The SPLASH Project, led by NASA Project Manager Ellen Carpenter, will perform a series of water impact drop test of the NASA Orion crew module mockup with the heat shield from the spacecraft’s first flight test, Exploration Flight Test 1 (EFT-1). The integrated Orion mockup and EFT-1 heat shield will be tested in 2016 to simulate water landings during actual missions. According to the NASA SPLASH principle investigator, upcoming water impacts tests will provide the data needed to conduct a much more thorough and detailed assessment of the water landing models that was not possible with previous test capsules. Data retrieved will assist in understanding the loads that astronauts will experience when the actual Orion spacecraft lands in the ocean. According to Ellen Carpenter "It is important to use a heat shield that is similar to what will be used on future Orion flights so the data obtained from these tests can be used to validate computer models.”
STC staff understands the importance of the project and are putting forth their best efforts to help ensure quality, maintain schedule and prepare for successful water impact testing. That effort is exemplified by the following statement by the SPLASH Project Manager, Ellen Carpenter, “STC did an excellent job in getting the two heat shield 4-wire harnesses’ KPT connectors replaced, checked out and delivered to me by 1pm on Monday, which was earlier than they had planned. Their efforts kept us from getting too far behind schedule.”
STC staff understands the importance of the project and are putting forth their best efforts to help ensure quality, maintain schedule and prepare for successful water impact testing. That effort is exemplified by the following statement by the SPLASH Project Manager, Ellen Carpenter, “STC did an excellent job in getting the two heat shield 4-wire harnesses’ KPT connectors replaced, checked out and delivered to me by 1pm on Monday, which was earlier than they had planned. Their efforts kept us from getting too far behind schedule.”
Long hours and constant effort have been put in by the STC staff, especially from Eric May, Matt Stearman and Max Reid. They have been putting in 10 hour days, six days a week for months at a time. They have worked diligently, professionally, and proficiently, helping to solve problems and keep the project moving forward. For example, during the mating of the heat shield and the GTA, they had to make sure the pieces were aligned horizontally, vertically, rotationally and then angularly. During this effort, more than 400 holes were match drilled to assemble the mockup to the heat shield. Match drilling is the process of precisely drilling holes through hardware components and ensures that the parts align properly in the final assembly. This was no simple task, and the team had to design and fabricate integration hardware to connect the two pieces. With an accuracy of four thousandths of an inch, a laser tracker located several positions along the Orion mockup and heat shield in order to achieve nearly perfect alignment. Ellen Carpenter has been pleased with STC efforts and had this to say, “STC technicians Eric May and Max Reid continue to do an outstanding job preparing the vehicle for testing. This was demonstrated during the hardware build-up that led to the successful final mate between the GTA and heatshield. Eric’s leadership is exemplary; he always is thinking ahead and provides solutions, when challenges and problems are encountered. Their workmanship is excellent and they exceed expectations. They are dependable and go above and beyond to get the tasks accomplished within the schedule constraints.”
Drop tests will be conducted in the spring 2016 time frame and STC will continue to provide high quality workmanship, in support of the SPLASH project. STC will be available help with any issues that come up during testing and will help with the de-integration efforts of the GTA and heat shield following the water impact testing. STC, with its high standards has definitely made a SPLASH.
Drop tests will be conducted in the spring 2016 time frame and STC will continue to provide high quality workmanship, in support of the SPLASH project. STC will be available help with any issues that come up during testing and will help with the de-integration efforts of the GTA and heat shield following the water impact testing. STC, with its high standards has definitely made a SPLASH.