Space Sunday: Frank Borman – first to the Moon

Fank Borman during Suiting-up for the Apollo 8 mission, December 1968. Visible but blurred in the background is his crewmate, Jim Lovell. Credit: NASA (via You Tube)

Just a week after the passing of Apollo astronaut Ken Mattingly (see: Space Sunday: Remembering Ken Mattingly), came the news that another pioneering hero of spaceflight, Frank Borman, had passed away at the age of 95.

Born in Gary, Indiana on March 14, 1928 as the only child of Edwin Otto and Marjorie Borman, Frank Frederick Borman II considered Tucson, Arizona to be his home town after his family moved there whilst he was very young in order to ease the numerous sinus and mastoid problems he suffered in the colder, damper environment of Indiana.

By the age of 15 and in the mid-1940s, he was playing football for the high school team and, thanks to local flight instructor Bobbie Kroll, who took a shine to his enthusiasm for aviation, he has his student’s flying certificate and was a member of a local flying club. His aim was to levering his football playing into a scholarship so he might attend an out-of-state university offering a good course in aeronautical engineering.

Unfortunately, this did not work out and with graduation approaching and his family unable to afford to send him to a suitable university, he determined he’s have to enlist in the Army and later use his right to a college tuition under the GI Bill. However, a family friend persuaded local congressman Richard F. Harless to add Borman’s name to a list of nominees he was going to put forward for a slot at the US Military Academy, West Point.

Borman’s official 1950 West Point yearbook photo. Via Wikipedia

Despite having little chance of being offered the slot – his was the fourth and last name on the list, after all – Borman took the entrance exam, and passed. Shortly afterwards, hostilities in the Pacific ended, and astoundingly, those on the list ahead of him opted to forego military service, gifting the slot to him.

Graduating West Point in June 1950, Borman returned home to Tucson on leave prior to commencing his formal basic training. Whilst there, he arranged to meet Susan Bugbee, whom he had dated in high school. She had recently graduated from the University of Pennsylvania with a degree in dental hygiene. Rekindling their relationship, they were married on July 20th, 1950.

Achieving his goal of training as a fighter pilot, Borman attended combat flight school throughout most of 1951, based at Nellis Air Force Base, Nevada. Whilst there, Susan gave birth to their first son, Frederick Pearce Borman, in October of that year. Two months later, Borman found his flying career potentially shattered after he suffered a perforated eardrum whilst on a dive bombing training flight and doctors grounded him indefinitely as a result.

It took him a year to convince his seniors his ear had healed without any danger of further ruptures,  and he was capable of flying. During that time, he was assigned to ground duties at Clark Air Base in Philippines, where Susan gave birth to their second son, Edwin Sloan.

By 1960 and with a Masters degree under his belt – which he obtained in just a year rather than the usual 3 – Borman had been back in the pilot’s seat for eight years, clocking up some impressive experience, all of which resulted in his selection for training USAF Experimental Flight Test School. Graduating from it April 1961, he was immediately selected as one of five Air Force students to attend the first class at the Aerospace Research Pilot School. However, NASA also announced they were seeking nine candidates for their second astronaut intake, so Borman, along with fellow student James McDivitt and instructor Thomas Stafford obtained permission to apply, and all three were formally accepted as a members of the “Next Nine” (Group 2) NASA astronaut candidates in April 1962.

At NASA, Borman became known for his focus and tenacity – and for have something of an ego. He was initially selected to fly with Mercury veteran Virgil “Gus” Grissom on the first long-duration flight of Gemini. However, their pairing as the back-up crew for Gemini 3, the first Gemini Project crewed mission, led to tensions such that when astronaut chief Donald “Deke” Slayton wanted to promote both men to the prime crew slots on the mission after original mission commander Alan Shepard was diagnosed with Ménière’s disease, Grissom stated he would only fly the mission if Borman were replaced as his pilot.

Complying with the request, Slayton replaced Borman with John Young. This scored two goals: it ended the friction between Grissom and Borman and it allowed him to appoint Borman as commander of the long-duration Gemini flight – now designated Gemini 7 – with Jim Lovell as his pilot, the two getting on well together. Plans changed just two months ahead of Gemini 7’s December 1965 launch, when Gemini 6 was cancelled while the crew of Walter Schirra and Thomas Stafford were actually in their capsule preparing for launch.

The reason for this was Gemini 6 has been due to perform rendezvous and docking tests with a uncrewed Agena Target Vehicle launch just ahead of it. However, the Agena had exploded shortly after launch, leaving Gemini 6 without a docking target. However, rather than drop the mission entirely, mission planners decided Gemini 6 – re-designated as Gemini 6A – could launch a few days after Gemini 7, with Schirra and Stafford using it as their rendezvous and docking target.

Borman agreed to this change, but drew the line at any idea of the two craft physically docking; he and Lovell didn’t have the time they’d need to learn the required procedures, even if their vehicle were to be the passive element of any docking. He also mixed the idea that Lovell and Stafford should perform and joint EVA and swap vehicles, pointing out this would require Lovell to wear a Gemini EVA suit for several days, something for which it was not designed. Conceding these points, mission planners settled on the basic rendezvous idea, and Gemini 7 lifted off on December 4th, 1965, with Gemini 6A following on December 15th – three days later than planned.

Gemini 7 with Borman and Lovell aboard, as seen from Gemini 6A, shortly after their initial rendezvous, December 15/16, 1965, when the two craft are approximately 10 metres apart. Credit: NASA

During the intervening period, Borman and Lovell completed all the major aspects of their mission – which were related to matter of crew hygiene, nutrition, fitness, diet, etc., during a lunar mission – and were keen to see Gemini 6A arrive. This it did some 13 hours after launch, with Schirra initially bringing the craft alongside Gemini 7 at a distance of 40 metres before spend the next 4.5 hours performing a series of rendezvous manoeuvres, at times coming as close as 30 cm (1 ft) to Gemini 7 as he practiced docking manoeuvres and assessed flight control precision. After this, he moved Gemini 6A some 16 km away to allow both crews to get some rest without any worry their vehicles might collide.

After just over 24 hours in orbit, Gemini 6A fired its retro-rockets and re-entered the atmosphere, splashing down in the North Atlantic to be recovered by the USS Wasp. Meanwhile Borman and Lovell continued in orbit, becoming concerned as their craft started experiencing a mounting series of niggling issues and malfunctions as it started to reach the limits of its operational endurance. Despite this, both men remained in good spirits, even joking with their recovery crew – their December 18th splashdown was close enough to that of Gemini 6A that the USS Wasp was also assigned to their recovery – that they’d been together so long, the Wasp’s Captain might as well marry them!

James Lovell (left, with son Jay) and Frank Borman (right, with wife Susan and sons Frederick and Edwin), following the successful flight of Gemini 7

Continue reading “Space Sunday: Frank Borman – first to the Moon”

Space Sunday: remembering Ken Mattingly

As it might have been: a NASA portrait of the original Apollo 13 crew with Ken Mattingly flanked by Jim Lovell, the mission commander (l) and Fred Haise, the Lunar Module pilot (r). Mattingly was later dropped from the mission ahead of launch due to fears of illness. Credit: NASA

On November 3rd 2023, NASA announced that Apollo and shuttle era astronaut Thomas Kenneth “Ken” Mattingly II, had passed away on October 31st, 2023 at the age of 87.

Perhaps best known, courtesy of Ron Howard’s film and his portrayal by Gary Sinise, for the mission he never actually flew, that of Apollo 13, Mattingly did participate in the penultimate Apollo mission to the Moon – Apollo 16 – and also flew two space shuttle missions in the 1980s.

Born on March 17, 1936, in ChicagoIllinois, Mattingly grew up with aviation in his blood, his father being employed by Eastern Airlines, and came to see it as a natural choice of career, opting to study for and achieve a BSc in aeronautical engineering prior to joining the US Navy in 1958 and applying for flight school.

Graduating as an attack aircraft pilot in 1960, Mattingly served first in VA-35 based out of Virginia, with an at-sea rotation aboard the USS Saratoga. Following this he was assigned to the heavy attack / reconnaissance squadron VAH-11 with his rotations split between the USS Franklin D. Roosevelt and Naval Air Station Sanford, Florida. It was whilst at the latter that Mattingly accepted an invitation to share a flight an a fellow aviator in his squadron had been ordered to take in order to gather aerial photographs of the launch of Gemini 3 out of Cape Canaveral in March 1965.

Shortly after this, and having being refused admission into the Navy’s Test Pilot School due to his assignment at VAH-11 finishing after the class of ’65 had commenced, he accepted a slot with the US Air Force Aerospace Research Pilot School. While primarily a USAF school, this also took on pilots from both the Navy and the civilian sector for courses, and in joining, Mattingly found himself training alongside future astronauts “Ed” Mitchell and Karol Bobko whilst receiving instruction under future astronauts Charles Duke and Henry W. “Hank” Hartsfield Jr.

Ken Mattingly posing for an official Apollo 16 photo. Credit: NASA

All of this had an impact on Mattingly, who applied for and was accepted into the NASA Group 5 astronaut intake of 1966. Coincidentally, his final selection interview was chaired by John W. “Jim” Young – one of the crew of the Gemini 3 mission he had watched launch whilst riding the photographic mission – and Michael Collins. It was an event he didn’t feel he’d fared well at, thinking he annoyed Collins and felt “perplexed” by Young’s attitude.

Following initial training, Mattingly was selected as part of the back-up crew for Apollo 8 and served as CapCom (capsule communicator – the individual charged with communicating directly with a crew in space) for that mission. He then worked with Michael Collins during the training cycle for Apollo 11, having being assigned as Collins’ “second” back-up after Bill Anders. As there was a risk that the mission could slip from July 1969 and into August  – and Anders would be leaving NASA during that month – Mattingly was put on the back-up roster and training in case the mission did slip beyond Anders’ departure and Collins was unable to fly for some reason.

That he was assigned the joint back-up position on Apollo 11 also meant Mattingly took over Anders’ spot as Command Module pilot for Apollo 13, continuing the loose partnership started with Jim Lovell (Apollo 13 commander) and Fred Haise (Lunar Module pilot). They formed a particularly good team together, but plans had to change three days ahead of the launch after Mattingly revealed he’s be exposed to someone with rubella. Standard policy called for his back-up for the mission (John “Jack” Swigert) to replace him to avoid any complications caused should he fall ill during the mission.

As a result of this, Mattingly was on the ground following the explosion which crippled Apollo 13’s Service Module. He immediately joined the teams ordered to recover the mission, using his knowledge of various simulations to suggest who could be called upon to provide specific expertise – such as cobbling together an air circulation system between command module and lunar lander.

After the command module had to be completely powered-down in the hope of conserving the battery power it would need in order to successfully re-enter the atmosphere and deploy its parachutes, Mattingly was assigned to the team charged with working out exactly how to re-start the command module’s electrical and guidance systems, given this was part of their design parameters – and to do so with a very limited power budget.

In the film Apollo 13 this saw Mattingly – as played by Gary Sinise largely leading the way in this work and bouncing in and out of the simulator. However, as the real Mattingly was quick to point out after seeing the film, reality was a lot less dramatic, comprising working through reams of documentation and data on the Command Module with a team led by Flight Controller John Aaron, and using the information to slowly and methodically write-up a clear set of procedures to bring the Command Module back to life. Only after this was all done was there any simulator hopping

We said, “Let’s get somebody cold to go run the procedures.” So I think it was [Thomas P.] Stafford, [Joe H.] Engle — I don’t know who was the third person, might have been [Stuart A.] Roosa. But anyhow, they went to the simulator there at JSC and we handed them these big written procedures and said, “Here. We’re going to call these out to you, and we want you to go through, just like Jack will. We’ll read it up to you. See if there are nomenclatures that we have made confusing or whatever. Just wring it out. See if there’s anything in the process that doesn’t work

– Ken Mattingly on developing the restart procedures for the Apollo 13 Command Module

Mattingly, at the CapCom desk in the Apollo Mission Operations Control Room, watches the screens after the successful splashdown and recovery of the Apollo 13 crew, April 17th, 1970. Credit: NASA via Getty Images

That the vetting of the procedures went smoothly and afterwards, Fred Haise on Apollo 13 was able to receive them over the radio and follow them without major hiccup is testament to the speed and care with which Mattingly, Aaron and their team were able to work, bringing together the final vital part of the puzzle together in order to bring the crew home.Mattingly finally got to orbit the Moon in April 1972 as the Command Module pilot for Apollo 16. By another of the quirks of fate which seemed to mark his entire career, his commander for that mission was Jim Young and the Lunar module Pilot was fellow Aerospace Research Pilot School instructor Charles Duke. While the latter went down to the surface of the Moon, Mattingly remained in orbit, performing a battery of experiments – some of which required he complete a EVA during the return leg to Earth in order to collect film and data packages from equipment in the science bay of the Service Module.

Mattingly (l) with Mission Commander Jim Young (c) and Charles Duke (r), in training for Apollo 16. Credit: NASA via Getty Images

Opting to remain with NASA as Apollo’s lunar missions were rapidly wound-down (causing a number of his colleagues to depart the agency to go back to their military careers or the private sector), Mattingly rotated through a number of key positions in managing the development of the space shuttle. This led to his first shuttle mission assignment as commander of STS-4 in 1982.

This was a week-long mission – the final in a series of four so-called “test flights” – timed to end on Independence Day 1982, with the landing at Edwards Air Force Base, California serving as the backdrop for then President Ronald Regan to announce the Space Transportation System was to henceforth be regarded as “operational”. In another twist of fate the man selected to fly with Mattingly as the vehicle’s pilot, was none other the Hank Hartsfield, Mattingly’s other instructor from the Aerospace Research Pilot School and who was now subservient to Mattingly’s overall command (confusingly, and in difference to aviation, the pilot on most NASA missions is not the commander for the mission but rather the “co-pilot”).

Mattingly (second from left after Hartsfield) chats with former US President Ronald Regan on July 4th, 1982 following the fourth – and last – test flight for the shuttle programme, whilst former First Lady Nancy Regan admires the imposing bulk of the shuttle Columbia. Credit: NASA

Mattingly’s last flight to orbit came in January 1985, when he commanded the shuttle Discovery on mission, STS-51-C. This flight is chiefly remembered for two reasons: it was the first shuttle flight to be classified by the US Department of Defense, and it is the shortest shuttle mission on record – just 3 days. However, it also has two haunting links with the loss of the shuttle Challenger on mission STS-51-L just a year later. The first being that 51-C was the first (and tragically last) on-orbit mission for Ellison S. Onizuka, one of those killed during 51-L.

The second was that 51-C revealed the dangers inherent in launching a shuttle during extremely cold weather – if people had been willing to see the signs for what they were. At the time of its launch, Discovery lifted-off in the coldest temperatures recorded for a shuttle flight up to that time: just 12 ºC. Following the recovery of the mission’s solid rocket boosters, it was found that all of the o-rings on both boosters showed signed of charring as a result of exposure to flame – with one of the primary rings entirely burnt through and its secondary badly burnt.

Tests subsequently showed that in low temperatures, this rings – designed to seal the joints between the major segments of the solid rocket boosters – both lose their ability to flex in response to dynamic pressures exerted both from within the boosters as they burn their propellants and from the surround air through which the shuttle system is trying to punch its way, and they become brittle and subject to burn-through. Despite these findings, Challenger was allowed to launch on mission 51-L after it had been exposed to temperatures fifteen degrees lower than those experienced at the launch of STS-51-C – and tragedy followed.

The crew of STS-51-C. Back row (l to right) Gary E. Payton, payload specialist; and mission specialists James F. Buchli, and Ellison L. Onizuka. Kneeling: mission pilot Loren J. Schriver, pilot; and Thomas K. Mattingly, II, commander. Credit: NASA

Continue reading “Space Sunday: remembering Ken Mattingly”

Space Sunday: Jovian Moons, and lunar aspirations

A volcanic eruption on Io, the innermost of Jupiter’s four Galilean moons, as witnessed by NASA’s Galileo spacecraft during the multi-year mission of the same name exploration the system. Credit: NASA

We’re probably all familiar with the concept of some Moons within our solar system  – notably Saturn’s Enceladus, and Jupiter’s Europa, Ganymede and Callisto – potentially being completely encompassed by a liquid water (or at least a slushy) ocean under their surfaces. But how about a moon being almost completely encompassed by an ocean of hot volcanic magma just a few kilometres under its surface?

That’s the proposal contained within a new paper written under the auspices of NASA’s Jet Propulsion Laboratory, and based on an analysis of data obtained by the Jovial Infrared Auroral Mapper (JIRAM) instrument aboard NASA’s Juno mission in reference to Io, the innermost of the four Galilean moons of Jupiter.

Of course, we’ve long known that Io, a moon slightly larger than our own, is the most volcanic place in the solar system. More than 400 active volcanoes have been identified since we first witnessed one erupting in 1979, courtesy of NASA’s by Voyager 1 in 1979, and the Juno mission has imaged no fewer than 266 actively erupting during its periodic fly-bys of Io as it studies Jupiter and its moons. The overall driving force behind these volcanoes is tidal flexing deep within Io’s core and mantle, the results of the moon being in a constant state of flux thanks to the gravitational influences of (most particularly) Jupiter to one side and the three other Galilean satellites on the other.

The comparative sizes of the Moon and Io, together with that of Earth to scale. Credit: full Moon – Gregory H. Revera; true colour image of Io – NASA/JPL; Earth: NASA / Apollo 17

However, there has always been something of a question as to how these volcanoes might – or might not – be related and directly powered. Here on Earth, volcanism usually occurs as a result of decompression melting within the asthenosphere – the upper limits of the mantle directly under the lithosphere/crust comprising solid and partially-melted rock. This gives rise to magma, which is then forced upwards through the lithosphere as localised volcanic eruptions. This was long held to be the case with Io, with scientists believing its volcanoes, like the majority on Earth, were driven by the upwelling of individual magma flows.

But during the Galileo spacecraft’s observations of Io between 1995 and 2003, the data gave tantalising hints that Io’s volcanism could be the result of a somewhat different process, but it has taken the unique capabilities of the Juno spacecraft to confirm this to be the case. By gathering extensive thermal and infrared imaging of Io’s mantle, the JIRAM instrument has been able to put together a comprehensive view of the upper layers of Io’s mantle, revealing that far from being a layer mix of solid and partially melted rock, Io’s asthenospheric region is entirely molten in nature.

In other words, lying just below Io’s lithosphere (roughly 12-40 km thick) is a moon-girdling ocean of magma, some 50 km thick, with a mean temperature of some 1,200ºC, and which powers all of Io’s active volcanoes.

The structure of Io as likely confirmed by data obtained by the JIRAM instrument aboard the Juno spacecraft. Credit: Kelvinsong

This may not sound exciting in the scheme of things, but it further demonstrates the uniqueness and complexity to be found within the Jovian system.

A further example of this can be found with Io’s big brother, Ganymede. The third of the Galilean moons in terms of distance from Jupiter, Ganymede is not only the biggest of the Galilean moons orbiting Jupiter, it is the biggest and most massive natural satellite in the solar system. In fact, if it were orbiting the Sun rather than Jupiter, it would be classified as a planet, being even larger than Mercury.

Ganymede, like its smaller siblings around Jupiter – and the rocky planets of the inner solar system – is a complex place enjoying a complicated relationship with its parent; one which shares near-similarities with Earth’s relationship to the Sun.

Much has long been known about Ganymede as a result of observations made from Earth – such as via the Hubble Space Telescope – and by the various missions which have flown past or orbited Jupiter. These have helped us confirm that Ganymede has a sufficiently warm interior to support a global liquid water ocean beneath its crust, an ocean larger by volume than all of Earth’s combined.

The comparative sizes of the Moon and Io, together with that of Earth to scale. Credit: full Moon – Gregory H. Revera; true colour image of Ganymede – NASA/JPL; Earth: NASA / Apollo 17

We’ve also been able to (largely) confirm the presence of a tenuous atmosphere of oxygen and CO2, which seems to be particularly concentrated around the northern and southern latitudes, likely constrained by the interaction between Ganymede’s weak magnetic field and the far more powerful magnetic field generated by Jupiter – the predominant O2 content of the atmosphere is thought to be the result of water vapour escaping the moon’s interior being spilt by the radiation carried down over the poles by the magnetic field interaction.

It is this interaction between radiation, magnetic fields and the surface of Ganymede which have been part of the focus of a study made of the moon using instruments on the James Webb Space Telescope (JWST), and which was recently published.

Ganymede’s surface is dominated by two types of terrain: bright, icy features with grooves, covering about two-thirds of Ganymede’s surface, and older, well-cratered and darker regions )on places scored by asteroid impacts of the moon’s more “recent” past, which could not be confused with the brighter terrain) . The two terrain types are not differentiated in terms of their location on Ganymede’s surface, they are instead intermingled, with the lighter terrain cutting swathes across the darker terrain.

Ganymede, showing its dominant types of terrain. The dark cratered regions, and the brighter, icy regions with grooved terrain. The white radial lines are the results of impacts with the moon and not directly related to the terrain types. Credit: NOAA

Some of these brighter swathes – notably those around the Polar Regions – carry strong evidence of water ice, which appears to have been exposed by (in the words of the study) “the combination of micro-meteoroid gardening, excavating the ice, and ion irradiation”.

In other words, over the millennia, dust and material has been caught within the interactions between the two magnetic fields, smashing into the moon’s surface to expose the underlying water ice, allowing it to be irradiated by plasma also carried by the inflowing magnetic field, causing some of it to escape as water vapour which has been either further irradiated and broken down (thus giving rise to the accumulation of the tenuous, O2-rich atmosphere near the surface), or re-accreting as easily-identified water ice on the surface rock.

Whilst the two magnetic fields interact around Ganymede’s poles and along the moon’s “trailing edge” as it orbits Jupiter in a very similar manner to the interaction between Earth’s magnetic field and that of the Sun over our own poles, the spectral properties seen along the moon’s ”leading edge” in its orbit suggest that there is a far more complex, and yet to be understood interaction taking place between the magnetic fields of planet and satellite. Solving this mystery might require time – and some assistance in the form of the European Space Agency’s Jupiter Icy Moons Explorer (JUICE) mission launched in April 2023, and due to reach the Jovian system in 2031, where it will likely uncover more surprises about both Ganymede and Europa.

Continue reading “Space Sunday: Jovian Moons, and lunar aspirations”

Space Sunday: 3D printing for space, and asteroids

A RAMFIRE rocket engine nozzle performs a hot fire test at NASA’s Marshall Space Centre, demonstrating the viability of 3D printed, aluminium rocket nozzles. Credit: NASA

3D printing may be a relatively new technology, but it is one that is revolutionising may sectors of industry and commerce – and that includes space exploration. I’ve already covered the work of Relatively Space to manufacture and operate the world’s first 3D printed rocket systems in the form of the (now retired after it maiden launch failure) Terran 1, and the highly ambitious, semi-reusable Tarran R. However, NASA has actually been charting the potential for 3D printing in space and on Earth for almost a decade.

As an example of this; the first 3D printing system installed on the ISS arrived in 2014. It was a modest affair primarily designed to research whether or not practical, plastic-based 3D printing could be used in the microgravity of space. As the analysis of the printed parts demonstrated, there were no weaknesses or deficiencies in their construction when compared to identical items produced on Earth using the same process. Thus, the initial project was expanded to encompass the production of usable items – a wrench, plastic brackets, parts of an antenna system, for example – using a variety of industrial-grade plastic filaments.

ESA astronaut Samantha Cristoforetti using the 3D Printer aboard the ISS. Credit: NASA

The capability was then enhanced with the arrival of ReFabricator – a system which could take plastics used on the ISS and recycle them into plastic filament for use by the printer, with Recycler later adding the ability to do the same with other “waste” materials on the station.

In 2023, the European Space Agency and Airbus Industries went a stage further with Metal3D, a printer capable of producing metal and alloy parts for use on the ISS. It is part of a broader project to develop in-situ orbital and lunar 3D printing systems capable of manufacturing everything from replacement parts to entire assemblies such as radiation shields, vehicle trusses, etc. ESA plan to use an enhanced Metal3D system to use lunar regolith as its raw material in the production of equipment and components.

Meanwhile, NASA has also been busy on Earth with a range of 3D printing projects and studies, one of which  – RAMFIRE – which earlier in the year had its (quite literal) baptism of fire.

Standing for the Reactive Additive Manufacturing for the Fourth Industrial Revolution,  RAMFIRE is a unique process which combines an entirely new aluminium alloy called 6061-RAM and 3D printing to create rocket nozzles for space vehicles. To understand why it is potentially so revolutionary, three points need to be understood:

  • As a rule, aluminium is a poor choice for rocket engine (and particularly engine nozzle) construction as it has a rather nasty habit of melting when exposed to high temperatures – such as those generated by a rocket engine nozzle.
  • While aluminium can be strengthened to withstand higher temperatures through the use of additives, the additives themselves can make it susceptible to cracking and microfractures if the aluminium has to be wield to itself or other items as is again required in the production of rocket nozzles.
  • At the same time, being able to print an entire engine nozzle as a single unit and in aluminium, has the potential of both greatly simplifying the process of rocket engine production (as the nozzle now comprises a single part, rather than up to 1,000 individual parts as is currently the case, and for the engine to be significantly lighter without any reduction in thrust, allowing for a potentially large payload to be carried.

Using 6061-RAM with a 3D printing process developed in partnership with Colorado-based Elementum 3D, NASA has been able to produce single-piece aluminium rocket nozzles which, by a combination of the additives used in the alloy and a series of special cooling channels printed into the nozzles, both withstand the heat of combustion in their chambers and also passively cool themselves in the process.

Over the summer period, two small-scale RAMFIRE nozzles were put through their paces at NASA’s Marshall Space Centre in a series of hot fire tests, the results of which were published by NASA on October 16th. The nozzles were tested using two cryogenic propellant mixes – liquid oxygen and liquid hydrogen in one batch of tests, and liquid oxygen and liquid methane in the other. It had been anticipated the nozzles would manage a pressure of up to 625 psi in their chambers, and run for a handful of minutes apiece. As it turned out, they functioned above the anticipated pressure without damage and racked up a cumulative burn time of almost 10 minutes.

This level of burn time and pressure is well in excess of the major requirement for such engine nozzles: within cargo transports carrying payloads to the surface of the Moon and landing them safely, bore lifting off again for the return trip to Earth to collect more cargo. However, the technology being developed by NASA and Elementum 3D has the potential to be used in a wide range of space vehicle applications, from propellant tank manufacture through to providing a means to provide very lightweight, thrust-efficient aerospike engines, one of the holy grails of space transportation systems.

The 6061-RAM2 aluminium and its associated 3D printing process also has the potential to produce other items required by spacecraft. The above is a demonstrator for a single-piece printed propellant tank, complete with the same cooling channels to help keep cryogenic propellants cold. The result is a lightweight single-piece tank structure with primary side walls just 1.5 mm thick.  Credit: NASA

There is still further R&D to go with RAMFIRE, but NASA and Elementum 3D are already looking at licensing 6061-RAM and the printing process to commercial organisations interested in adapting it for use in their space-based efforts  – and possibly further afield in aerospace research sectors.

Continue reading “Space Sunday: 3D printing for space, and asteroids”

Space Sunday: a bit of a round-up

The outside of the sample container from OSIRIS-REx showing material from asteroid 101955 Bennu scattered outside of the container proper, testament to the amounts contained within. Credit: NASA / Erika Blumenfeld & Joseph Aebersold

On October 11th, 2023, NASA revealed details of their first look at samples returned from asteroid 101955 Bennu, returned to Earth on September 24th by the OSIRIS-REx mission.

As I reported in Space Sunday: the return of OSIRIS-REx, the sample return capsule carried with it up to 250 grams of material from the carbonaceous asteroid – a lot more than had been anticipated, thanks to Bennu proving to be so brittle the sample mechanism smashed through its outer surface, clogging itself with material, rather than lightly “tapping, grabbing and departing”.

The sample container now open (left), with more materials coating the inner surfaces (right). This material was used in the initial analysis of the sample. Credit: NASA

Following its recovery after landing in Utah, the capsule and containing the sample gathering head from the spacecraft was transferred to Johnson Space Centre and the Astromaterials Research and Exploration Science (ARES) centre (as I reported here), where for the last couple of weeks the sample container has been accessed and its contents subject to initial analysis.

It has still not been confirmed how much material has been obtained from Bennu; the opening of the sample canister revealed a fair amount of material was trapped between the lid of the canister and the membrane protecting the main bulk of the sample. This was painstakingly collected and formed the materials used for the initial analysis of the sample dust.

This initial analysis as revealed that – as expected, given it is a carbonaceous asteroid – the sample has within it evidence of both carbon and water, with the latter have a similar isotopic levels similar to those of Earth’s oceans. This was expected as it has long been the theory – supported by the examination of other asteroid samples returned to Earth by Japan’s Hayabusha and Hayabusha-2 missions – that C(arbonaceous)-type asteroids were responsible for bringing water and carbon to Earth early in its history.

Mari Montoya (left) and Curtis Calva at NASA’s Astromaterials Research and Exploration Science (ARES) centre carefully collect all the overspill from the OSIRIS-REx sample container, carefully clearing it all so it can be used in the initial analysis of the material returned from 101955  Bennu. Credit: NASA

Which is not to say that the samples do not offer a lot to learn; there is much that scientists do not know for certain about the Earth’s earliest history and its formation; much of what we do know is basis on hypotheses and scientific assumptions. The study of samples like those from Bennu samples could therefore allow many of those hypotheses to to more fully tested and the knowledge we lack or assume to be correct properly framed and understood.

Following extraction, the material from inside the sample container will be distributed to research centres in museums and universities around the world to enable a more extensive and as broad-ranging spectrum of independent analysis as possible over the coming months / years.

Psyche Launched

Following on from my previous Space Sunday article, and after being delayed almost 24 hours due to inclement weather, NASA’s mission to asteroid 16 Psyche got underway at 14:19 UTC on October 19th, 2023 when a Falcon Heavy lifted-off from Pad 39A at Kennedy Space Centre, Florida.

The SpaceX Falcon Heavy which launched the spacecraft Pysche at the start of its mission at Pad-39A, Kennedy Space Centre. Note the sooty exteriors of the side boosters, marking the fact both were about to make their fourth ascent each from a launch pad. Credit: NASA

After a flawless launch the rocket – comprising a core Falcon 9 booster with two additional first stages of the same rocket acting as strap-on boosters – rose into a cloudy sky over Florida. Just over two minutes into the flight, the side boosters separated to complete a “burn back” manoeuvre allowing them to return to Florida to land at Cape Canaveral Space Force Base adjacent to Kennedy Space Centre a few seconds apart, the landings marking the 4th successful flight for both units.

The spacecraft separated from the upper stage of the booster around an hour after launch, having been delivered to an extended orbit around Earth. There then followed a further 30 minute period of silence as the vehicle powered-up and oriented its communications system to call home with its first batch of data, indicating all was well and establishing a firm link with mission control.

The next 100 days will see the spacecraft comprehensively checked-out in terms of its flight systems – notably the four Hall-effect SPT-140 ion thrusters. This will be used serially throughout the flight to propel the vehicle to its rendezvous with 16 Pysche and enable it to slow down for an orbital rendezvous.

This checkout will be completed over the next week or so, and prior the vehicle being ordered to use the thrusters to start pushing itself away from Earth and into a heliocentric orbit around the Sun to reach Mays in 2026. Once there, it will use the planet’s gravity to help swing itself onto an intercept with 16 Psyche, where it will arrive in the latter part of 2029 to commence its science operations over an initial 21-month period.

A view from the forward end of the Falcon Heavy upper stage showing the departing Psyche spacecraft, the 24-metre span of its solar arrays still stowed. Credit: SpaceX / NASA TV

As I noted last time around, the journey to Mars will see NASA carry out a test of their Deep Space Optical Communications (DSOC) laser communications system, which could greatly increase the data rate and bandwidth of communications used with deep-space missions. The first test for DSOC should come in about three weeks from launch, when the vehicle will be 7.5 million kilometres from Earth. They will then be periodically repeated and extended as the spacecraft reaches a distance of to 2.5 AU from Earth.

The launch marked the eighth for what is now the world’s second most powerful launch vehicle currently regarded as operational (the most powerful title having been taken by NASA’s Space Launch System), and the 4th for 2023. However, it was particularly noteworthy for SpaceX, as it marks the first time NASA has used the rocket, and several concessions had to be made in order for this to go ahead.

The booster is also set to become a mainstay for several major NASA missions over the next few years. These comprise the launch of the 2.8 tonne GOES-U weather satellite and Europa Clipper mission to the Jovian system (both in 2024), the Nancy Grace Roman Space Telescope in 2026/7 and – perhaps critically for NASA’s human spaceflight operations, the joint launch of the first two sections of the Lunar Gateway Station in the form of the Power and Propulsion Element (PPE) and the Habitat And Logistics Outpost (HALO), a launch currently targeted for November 2025.

In this, and in difference to the hype and questionable capabilities of the SpaceX Starship / Super Heavy system, Falcon Heavy is proving itself as reliable a launch vehicle as the rocket from which it has been formed.

Continue reading “Space Sunday: a bit of a round-up”

Space Sunday: Psyche and an eclipse

An artist’s impression of the Psyche mission spacecraft observing and mapping the asteroid 16 Psyche. Credit: NASA

Asteroids have been something of a focus for Space Sunday of late, and they’re going to be again this week. Or at least, one is: 16 Psyche, as this is the target for a NASA mission which, if all goes according to plan, will launch from Kennedy Space Centre on October 12th, 2023.

16 Psyche was discovered by the Italian astronomer Annibale de Gasparis on 17th March 1852, and is named for the ancient Greek goddess of the soul. It has a shape consistent with that of a Jacobi ellipsoid, and measures some 278 km x 238 km x 171 km as it orbits the Sun between Mars and Jupiter once every 4.9 years at an average distance of 437 million km (2.92 AU). It is also the 16th minor planet to be found in the solar system by order of discovery (hence the 16 in its name).

What 16 Psyche might look like. Credit NASA

But what makes 16 Psyche a subject for detailed study is the fact that it is the largest and most massive M-class asteroid – a class of asteroids which appear to contain higher concentrations of metal phases (e.g. iron-nickel) than others within the asteroid belt – yet discovered in the solar system. So massive in fact, that it was long theorised that it was the exposed core of a protoplanet.  These are bodies thought to have been created during the early history of the solar system from the collision and coalescing of planetismals, and which may have gone on to play a role in the formation of the inner planets of the solar system (in fact, for a time in the early 20th century, the coalescing of planetismals into protoplanets and protoplanets into planets was thought to be the process by which all planets were created, an idea long since proven incorrect; planetary formation is far more complex than things bumping into one another and gluing themselves together).

Thus, it is also possible that whilst a protoplanet, 16 Psyche evolved along lines which had nothing to do with planetary formation; thus, studying it might either help in our understanding of planetary formation and / or enable us to more fully understand the unique processes at work within these tiny (in terms to their relationship with planets) bodies, and the mechanisms which ultimate gave rise to their form and nature. Most intriguingly, a mission to 16 Psyche might even point to a different story as to how objects in the solar system formed.

What we do know about 16 Psyche’s surface details, based on observations via the European Southern Observatory’s Very Large Telescope in the Atacama Desert, Chile. Credit: ESO

Hence the upcoming NASA mission and spacecraft which bear the asteroid’s name. First proposed in February 2015 by Arizona State University, the idea was awarded a US $13 million grant under the agency’s ongoing Discovery Programme to allow the basic concept to be fully evaluated and the initial design for the spacecraft determined. As a result of this, the mission was officially adopted into the Discovery Programme at the start of 2017 with a budget capped at $1 billion.

At that time, the mission was targeting a later 2023 launch date; but such was the confidence in the vehicle’s development cycle that this was revised to a July 2022 launch opportunity. This would allow for a much faster mission, drastically reducing the transit time to 16 Psyche, allowing the spacecraft to reach it in 2026, rather than 2029 as would be the case with a 2023 launch. Unfortunately, COVID-19 intervened to delay the construction and testing of the spacecraft, forcing NASA to push the launch date back to October 5th, 2023. Then in September 2023, this was delayed a further week to allow time for adjustments made to the operational parameters for the spacecraft’s cold gas thrusters (used to orient the craft when manoeuvring) to be properly checked and verified.

Psyche (as in the spacecraft) will commence its journey atop a SpaceX Falcon Heavy rocket due to lift off from Pad 39A, Kennedy Space Centre, Florida at 14:16 UTC on October 12th. Once the craft has separated from the Falcon Heavy’s upper stage, it will deploy its massive solar arrays – a span totalling 25 metres and 7.3 metres across at its widest. Capable of generating 21 kilowatts of electricity whilst in the vicinity of Earth (which will decrease over distance to between 2.3-2.4 kilowatts when the spacecraft is orbiting 16 Psyche), these panels will not only provide electrical power to Psyche’s instruments, but will also power the vehicle’s primary propulsion system.

A US SPT-140 Hall-effect thruster being tested at NASA’s Jet Propulsion Laboratory. Credit: NASA/Caltech

This comes in the form of four Hall-effect SPT-140 thrusters which will be used individually rather than collectively during the cruise stages of the mission, to both propel the spacecraft to its destination and slow it for orbital insertion around 16 Psyche. Each thruster uses some of the electricity generated by the solar panels to generate an electromagnetic field, which is in turn used to direct and accelerate a stream of inert xenon gas ions, expelling it as an exhaust mass to propel the craft.

The force of this exhaust is not huge – it’s about equal to that felt when holding an AA battery on the palm of the hand – but the key thing is, it can do so for weeks, and with a tiny amount of fuel, allowing for a constant acceleration, reducing the transit time to the asteroid compared to conventional meaning of transit (i.e. using momentum imparted by the launch vehicle coupled with multiple planetary flybys) and at a fraction of the propellent load (1 tonne or 10%)  that would be required if conventional chemical motors were to be used.

Even so, the journey to 16 Psyche will still the 2.6 tonne spacecraft take 5 years 10 months. The first part will be a 2-year, 7-month outward spiral around the Sun so the spacecraft can perform a flyby of Mars in May 2026. This will allow it to both accelerate and swing itself onto a trajectory which crosses that of 16 Psyche in 2029, allowing the vehicle to slow itself into an initial orbit around the asteroid in August of that year.

During the initial part of the outward cruise, the spacecraft will be used to demonstration a potential new deep space communications technology – DSOC (“dee-sock”), the Deep Space Optical Communications system. This is a laser-based system which, if it works as planned, will increase communications performance and efficiency between Earth and a spacecraft in deep space by between 10 and 100 times, simply because of the removal of signal attenuation compared to radio signals and the greater bandwidth / throughput rates lasers can provide. DSOC will initially be tested through the first 12 months of the mission and, subject to results, the demonstration may be extended into the second year of the vehicle’s cruise phase, allowing the capability to be tested over distances of up to 2.5 AU.

On arrival at 16 Psyche, the spacecraft will enter the first of five orbital regimes (one if which it will use twice) in order to thoroughly map and study the asteroid. In particular, these will attempt to probe any magnetic field the asteroid might have (the presence of such a field would greatly lend itself to the idea the asteroid is in fact the core or partial core of a protoplanet). They will also enable the craft to completely map the surface of 16 Psyche and determine its surface composition and properties.

Orbit Duration Inclination Period Duration Mission
A 92 days 90º 32.8 hours 700 km Magnetic field characterization and preliminary mapping
B(1) 92 days 90º 11.6 hours 303 km Topography and magnetic field characterization
D 100 days 160º 3.6 hours 75 km Determining the chemical composition of the surface
C 100 days 90º 7.2 hours 190 km Gravity investigations and Magnetic field observations
B(2) 100 days 90º 11.6 hours 303 km Topography and magnetic field characterization
Psyche orbital operations at 16 Psyche, 2029-2031. Credit: NASA

Given the nature of the spacecraft and allowing for its overall condition towards the end of the primary mission, it is possible that the Psyche mission could be extended beyond this initial 21-month period.

The launch of the Psyche mission will be broadcast by NASA TV, and can be watched via the link / preview below.

October 2023 Annular Eclipse

On Saturday, October 14th, 2023, nearly one billion people across the United States and the northern countries of South America will be able to watch an annular eclipse of the Sun (or at least a partial eclipse) – as the Moon crosses the Sun’s face as seen from Earth the last solar eclipse for 2023.

Annular solar eclipse seen from Chiayi in southern Taiwan on June 21st, 2020. Credit: Alberto Buzzola

An annular eclipse difference from a total eclipse in that the Sun is never completely hidden by the Moon. In the case of October 14th, this will be because  the Moon will be 4.5 days past apogee (the point where it is  farthest from Earth, and so the tip of its umbral shadow cone misses Earth by around 19,200 kilometres, so the disk of the Moon will appear too small to completely cover the Sun; around 48% of the Sun’s diameter remains visible all around the Moon’s disk, creating what can sometime be a spectacular “ring of fire”.

Those able to see an annular eclipse in the United States are located along a line commencing in Oregon and passing directly through Nevada, Utah, New Mexico  and Texas whilst touch the northeast of California and Arizona and the southwest of Colorado. In South America, the line of the eclipse passes through Mexico Nicaragua, Columbia and northernmost Brazil and touches on Costa Rica, Panama and Venezuela. Further afield, people will see a partial eclipse.

Track and times of the October 2023 annular eclipse across the United States (track across South America shown inset). Credit: NASA Scientific Visualization Studio

However, for those wishing to track the event, NASA’s 2023 Eclipse Explorer offers an interactive map detailing when and where the eclipse will be visible, including the path and duration of annularity (the areas from which the ‘ring of fire’ can be seen), allowing users to dive into the eclipse viewing experience like never before. Both the Time And Date and Virtual Telescope will be livestreaming the eclipse around the globe, as will Slooh via their You Tube Channel.

Of course, if you live along the line of the eclipse, you can always view it live. If you opt to do so (assuming the whether is clear), then remember: never look directly at the Sun either and especially through a telescope or binoculars or camera – don’t even use ordinary sunglasses. To view the eclipse safely you must use solar filters at all times on any optical equipment you are using to observe the Sun and / or wear solar eclipse glasses, regardless of whether your location will experience a partial solar eclipse or an annular solar eclipse. Serious eye damage and even blindness can result if you do not otherwise.

Also, don’t expect things to go really dark in the manner of a total eclipse or to be able to witness the Sun’s corona: that ring of the Sun’s disk peeping around the Moon may be small, but it is still bright enough to prevent that. But it will still be a spectacular event to see, and enthusiasts will go to whatever section of the eclipse track is most easily accessible for them in order to witness it.