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NASA Shuttle Replacement's Problems Are Worsening

ausoleil noted that NASA's replacement for the shuttle, the Orion, is slipping behind schedule "'We're probably going to have to move our target date,' NASA exploration chief Doug Cooke told The Associated Press on Wednesday after Nasawatch.com posted the 117-page internal status report (PDF) on the moon program. The cost problems include an $80 million overrun on a motor system. The Orion spacecraft's design remains too heavy for the proposed Ares 1 rocket. Software development, heat shield testing and other complex work remain behind schedule or over budget. There are dozens of such serious challenges, many of which are 'worsening.'"

40 of 344 comments (clear)

  1. yeah, that's right. i'm not a rocket scientist by Anonymous Coward · · Score: 5, Funny

    but i'll play one on slashdot and come up with all kinds of rubber band and duct tape solutions and act like my 11th grade physics class bests nasa engineers.

    wait, my friends, you'll see tons of posts just like this except for that the posters take themselves seriously.

    1. Re:yeah, that's right. i'm not a rocket scientist by sm62704 · · Score: 5, Informative

      but i'll play one on slashdot and come up with all kinds of rubber band and duct tape solutions

      You mean like the ones that saved Apollo 13? IIRC the solution to the problem of running out of breathable air involved rubber bands and duct tape.

      --
      mcgrew's razor: Never attribute to stupidity that which can be explained by greedy self-interest
    2. Re:yeah, that's right. i'm not a rocket scientist by dotancohen · · Score: 5, Funny

      IIRC the solution to the problem of running out of breathable air involved rubber bands and duct tape.

      Because duct tape can be bought on any budget. Hell, it better be the first thing on the budget. Hell, it's probably holding the budget together.

      --
      It is dangerous to be right when the government is wrong.
    3. Re:yeah, that's right. i'm not a rocket scientist by gunnk · · Score: 4, Insightful

      I'm not sure the problem is so much technical as process: the Orion is a "Cost Plus" contract.

      Cost plus is always likely to see cost overruns and major delays. The more expensive and the longer it takes, the more the contractors make. There's no motivation to be on time and under budget.

      --
      Life is short: void the warranty.
    4. Re:yeah, that's right. i'm not a rocket scientist by Anonymous Coward · · Score: 5, Interesting

      The more expensive and the longer it takes, the more the contractors make. There's no motivation to be on time and under budget.

      Not true... cost plus is good if you don't want the "lowest bidder" mentality. Although underhanded tactics will inevitably exist, NASA only pays contractors cost plus a FIXED profit for the contractor.

      They have no incentive to run over on the time

    5. Re:yeah, that's right. i'm not a rocket scientist by khallow · · Score: 4, Interesting

      If only it were that easy. Adding to the Cost usually means you're going to take a beating when it comes to determining the Plus. It's also not a great idea to willfully and purposely dick over a major customer like NASA; both because it's illegal and because you'll have no chance to win future contracts.

      I don't buy that. First, there's a long history of prime contractors (the ones actually able to make contracts with government agencies) screwing over federal agencies yet continuing to get contracts. Second, it looks pretty straightforward to legally exploit cost plus contracts.

  2. Fortunately for NASA by Hawthorne01 · · Score: 4, Insightful
    There are alternatives.

    Look, does this news really come as a surprise? NASA's been over-budget and behind schedule since the last Apollo flight. Without the unlimited checkbook that Mercury/Gemini/Apollo had, this should be expected.

    Unlimited budgets have a way of clearing all obstacles in their path.

    --
    "Only two things are infinite, the universe and human stupidity, and I'm not sure about the former."
    1. Re:Fortunately for NASA by maxume · · Score: 5, Informative

      The post office is, roughly, a crown corporation. It operates under a government mandate and follows some special rules regarding taxes, but it has been self funded for quite a long time now.

      --
      Nerd rage is the funniest rage.
    2. Re:Fortunately for NASA by Vornzog · · Score: 4, Insightful

      There are alternatives [spacex.com].

      Yeah, including some real alternatives, that can actually get into the orbits NASA needs to get to, rather then just barely out of the atmosphere (where you can tell a tourist that they are 'in space'. Like this or this.

      The US Government has already funded the development of not one, but two rockets with the kinds of capabilities they need. They are flight proven, expandable to handle all sorts of loads, and available right now, not whenever Ares will slip out to. Add a little redundancy in a couple of systems, and have them ready to launch American astronauts into space in two years.

      SpaceX is cool, and is probably the direction that the future of American space exploration needs to go. But it is not ready, it is not proven and it doesn't come close to the kinds of payload capacity or reliability that we need now. Check back around the time when Ares is supposed to be done to see what SpaceX is up to. In the mean time, quit screwing around developing a rocket similar, but slightly different from, the two perfectly good commercially available ones that are already up and running.

      --

      -V-

      Who can decide a priori? Nobody.
      -Sartre

    3. Re:Fortunately for NASA by Red+Flayer · · Score: 4, Interesting

      The post office is, roughly, a crown corporation. It operates under a government mandate and follows some special rules regarding taxes, but it has been self funded for quite a long time now.

      You should check the figures on that... it stopped being true some time ago. Email has killed the ability of the USPS to fund itself. It's really hard to track the USPS budget, for lots of reasons (for example, their 1st, 2nd, and 3rd quarters are 84 days long, and their 4th quarter is 112 days), but the Federal budget includes payments to the USPS for security and anti-terrorism, to make up for reduced revenue from Congressionally capped rates, and for other reasons.

      Suffice it to say that the USPS is no longer self-sufficient.

      --
      "Trolls they were, but filled with the evil will of their master: a fell race..." -- J.R.R. Tolkien on Olog-hai
  3. Gap? by justinmc · · Score: 4, Insightful

    How long will there be no active US manned spacecraft - and will this get longer?
    I am reminded of the gap between Apollo and the Shuttle - and look at what happened to Skylab...

    1. Re:Gap? by inviolet · · Score: 5, Insightful

      This is expected, though. Since when do projects half this scale go as planned? I just hope the Americans get their shit together and give Orion the funding it needs.

      Actually this kind of cost overrun is absolutely planned.

      You'd do it too, if faced with this alternative:

      • Propose to congress a project which will cost $40B, be truthful about the cost, and be rejected; or
      • Propose to congress a project which will cost $40B, lie and say it will cost $15B, and be approved. Later the cost will rise but Congress will not care, or will commit the "sunk cost fallacy".

      If you cared *nothing* for your country but just wanted to run a big project, then you would lie, get the money, and do the project. On the other hand, if you cared *dearly* for your country, and knew it needed a space program, then you would lie, get the money, and do the project.

      Ah well.

      I am finally at peace with this. What I will never be at peace with, however, is the fact that the space program is a mere drop in the bucket of market-distorting federal transfer payments.

      --
      FATMOUSE + YOU = FATMOUSE
    2. Re:Gap? by ColdWetDog · · Score: 4, Insightful

      This is expected, though. Since when do projects half this scale go as planned? I just hope the Americans get their shit together and give Orion the funding it needs.

      Somebody-or-others-law:

      A poorly planned project takes three times as long to complete as scheduled.

      A well planned project only takes twice as long.

      --
      Faster! Faster! Faster would be better!
    3. Re:Gap? by zippthorne · · Score: 4, Insightful

      The war is not about sunk cost. It hasn't been since we defeated the Iraqi regular army.

      It's about power gaps. Which, having taken over the country and destroyed their existing government, it would be irresponsible for us to simply leave the Iraqis to fend for themselves.

      --
      Can you be Even More Awesome?!
  4. What has happened to us? by Anonymous Coward · · Score: 5, Insightful

    We seemed more adventurous and capable in the 1960s than we are in 2008. Is this what has become of the great spacefaring nation that so many before us had envisioned? Despite serious technological advancements, have we lost our momentum? Maybe it was a passion for the unknown that enabled us before. I fear it has been replaced by disinterested private contractors, underfunding, and ambivalence. More so if this shuttle replacement isn't successful.

    1. Re:What has happened to us? by east+coast · · Score: 5, Insightful

      There's two major problems:

      1. Less funding. For as much as we use it as a dick wagging competition neither party has a real interest in seeing a very robust space program when those dollars could go to buying off voters with more useless ventures that put cash in the right pockets.

      2. Speaking of dick wagging competitions, we've lost our main rival. While the argument could be made that the Chinese are going to beat us up in the space race in another couple of decades, most people just aren't that interested. The space race is no longer a spectator sport since Crazy Ivan is now regarded as either friendly or impotent. The same Joe Sixpacks who shell out hundreds to thousands of dollars each year on their favorite football team were keeping interest in the space program alive when it was competitive. They love The Right Stuff, they yawn at 2001.

      --
      Dedicated Cthulhu Cultist since 4523 BC.
    2. Re:What has happened to us? by ShibaInu · · Score: 4, Insightful

      Let's also be clear that the need to put humans in space seems not so obvious any more. We have fleets of robots exploring other planets with less cost and less risk. To me, human exploration of space at this time seems like a waste. Right now the human space program seems more like a corporate boondoggle than anything else. Of course it is over budget, that is the whole point - to spend a lot of taxpayer money!

      With robots you can take more risk and spend more money. And, I'm not saying that humans shouldn't go into space, it just seems like right now we should be focused on exploration, which is better served with robots.

    3. Re:What has happened to us? by Waffle+Iron · · Score: 4, Informative

      The resource on the moon is the isotope He3. It might be useful for certain fusion scenarios. However, investing $billions now would be putting the cart before the horse.

      We don't know if *any* kind of hot or cold fusion will be feasible with any fuel. IIRC, He3 will be harder to fuse (but less radioactive) than the usual D/T combination. OTOH, there are other more abundant fuels, harder to fuse than He3, which would also have low radioactivity. We'll have to see which, if any, fusion reactors end up as workable possibilities.

      The He3 is in trace quantities distributed across the surface of the moon. Mining it would require gathering moon dirt in quantities comparable to the amount of coal mined here on earth, then distilling a few tons of He3 annually from these countless megatons of dust. This doesn't seem economical with any foreseeable space technology.

      The huge amounts of money it would take to develop this moon fuel capability would probably be better spent on fusion cycles that don't need He3, or other energy technologies altogether.

  5. The Intermediate Solution by WwWonka · · Score: 5, Funny

    NASA has reported that the delay and the budget crunch has forced it to reconsider a prior option that will now be built on the shores of Cocoa Beach, FL. It will include two one hundred foot towers with a very elastic synthetic band extending between them. A state of the art human reclining space momentum chair will be attached in the middle to propel future explorers into space...or some where father out into the Atlantic Ocean.

    1. Re:The Intermediate Solution by RabidMoose · · Score: 5, Funny

      This solution contains rubber bands, but is detrimentally lacking in duct tape.

  6. Shocker!!!!!! by Chineseyes · · Score: 4, Informative

    Engineering of a very complex systems overrunning budget and schedule limits and this is news?

    News would be if they were under budget and finished a year early.

    --
    I think the invisible hand of the market has its middle finger extended

    --A wise old fart named SC0RN
  7. Re:Just wait by smittyoneeach · · Score: 5, Interesting

    Just set up a national tip jar on something akin to PayPal.
    Citizens actually want to fund space activities, not the stuff that's killing us: http://perotcharts.com/
    Dis-intermediating DC is step #1 in carrying out the will of the people.

    --
    Get thee glass eyes, and, like a scurvy politician, seem to see things thou dost not.--King Lear
  8. Re:Did we really make it to the moon? by torkus · · Score: 4, Insightful

    Sure sure. Sounds great.

    Now, just initial here that the 2008 mandatory stress testing has been done on each component, OSHA has approved the ergonomics of the seats, all modern safety systems are in place...and...hello? Where are you going?

    No one (with power in NASA or gov't) is interested in getting back to the moon without a billion rules, regulations, and safety measures.

    --
    You can get rich if you own a politician, but you have to be rich to buy one in the first place.
  9. you get what you pay for by thrillseeker · · Score: 4, Insightful

    and we haven't paid for much of a space program for several decades now. All that engineering knowledge has slowly, and literally, died as engineers have retired. Sending a handful of people to earth orbit every year is not exploration - any focus on anything other than how to advance human beings as rapidly as possible to every body in the solar system is simply spending money without garnering public desire to pay for more of it. We need people going places, and waiting five decades to get around to making it happen has wasted away all the good will those who write the checks had for doing this business.

    1. Re:you get what you pay for by sm62704 · · Score: 4, Insightful

      I'm astounded at the number of people on a nerd site (of all places) who take "old sayings" unquestionably.

      Whoever believes that "you get what you pay for" has never prepaid for sex, or used an unlicensed contractor for home repairs. You usually pay for what you get, but you don't always get what you pay for. Often a higher priced item will be inferior to a lower priced item. Only a fool buys item A because it costs more than item B. Seller B may be trying to get market share.

      Money doesn't grow on trees, you know. Oh wait - yes, it does. It not only grows on trees, it grows on cornstalks and soybean bushes and all sorts of other plants.

      There's no such thing as a free lunch... excuse me, grandma's calling. What, grandma? Sure, I'll come over for lunch.

      Nothing free is worthwhile. Except maybe air. And rain. And those dandelion leaves in that expensive salad you just bought. Someone gave me some tomato plants, and guess what? Home grown tomatos are vastly superior to the ones I bought. Yes, It took fifteen minutes physical labor to plant them and I'll have to pick the tomatos, but that's not a cost, it's a benefit. I work at a desk job and don't get much exersize. Meanwhile I pay a fee for the gym.

      My dad always said "don't believe anything you hear, and only half of what you see". I think he's right, and I think it goes double for those incredibly stupid old sayings. Don't take anything on face value; at least give it half a thought.

      --
      mcgrew's razor: Never attribute to stupidity that which can be explained by greedy self-interest
  10. Meh. by susano_otter · · Score: 5, Insightful

    You should see the contortions Grumman had to go through, to get the Lunar Module under the mission weight budget, well into the Apollo Program.

    I figure the only thing that's changed between now and then is the Internet makes it much easier for the lay public to form entirely the wrong impression about highly complex and technical works-in-progress.

    --

    Any sufficiently well-organized community is indistinguishable from Government.

  11. Re:Did we really make it to the moon? by east+coast · · Score: 4, Insightful

    No one (with power in NASA or gov't) is interested in getting back to the moon without a billion rules, regulations, and safety measures.

    Also consider that astronauts were looked on as rough and tough guys doing their national duty in the days of Apollo. Today they're seen as geeks wasting cash on expensive toys.

    --
    Dedicated Cthulhu Cultist since 4523 BC.
  12. Re:I'm outraged? by dotancohen · · Score: 5, Informative

    The cost problems include an $80 million overrun on a motor system

    Well, that's sucks I guess. But since NASA has something like a $17 billion budget, isn't that a colossal non-issue? I realize this was just the motor system, but if I had a $40,000 budget to furnish a new home, I don't think I would be concerned if the coffee table was $20 more than I was expecting.

    From Wikipedia:
    "NASA's current FY 2008 budget of $17.318 billion represents about 0.6% of the $2.9 trillion United States federal budget."

    I'll let the reader come to his own conclusions about US priorities. Without linking to the DoD budget.

    --
    It is dangerous to be right when the government is wrong.
  13. Re:Just wait by AKAImBatman · · Score: 5, Informative

    I think you're confusing Ares I and Ares V. Ares I isn't all that big. It's a single stack of capsule -> fuel tank -> stage 2 engine -> stage 1 solid rocket booster. If anything, it's quite a bit thinner than most rockets. However, it does make up for this by towering a massive 94m high. Which does mean a few upgrades to the scaffolding.

    The Ares V, however, she's gonna be a beasty. With six (!) main engines, two outboard Solid Rocket Boosters, a plump width of 10m on the central stack, and a towering 116m tall, she's going to put every other rocket to shame. Personally, I can't wait. ;-)

  14. Why the Ares I? by mpthompson · · Score: 5, Insightful

    There are existing commercial launch vehicles such as the Delta IV or Atlas V rockets that can be man rated or the potential upcoming commercial launch vehicles such as the SpaceX Falcon 9 that could replace Ares I. Although man rating isn't trivial it's insane for NASA to create a new rocket to compete with existing commercial launch vehicles. NASA should encourage making manned access to low Earth orbit a low cost commercial commodity rather than using government resources to discourage such access.

    In fact, NASA should contract with two independent suppliers capable of lifting the CEV to low Earth orbit and buy launch vehicles from each supplier in near equal quantities. This would add some expense, but it would make sure that should a launch accident occur our manned space program isn't grounded for years as complex accident investigations occur and fixes are implemented on the failed launch vehicle.

    The Ares I is an albatross that only exists because of pride and politics. It is harmful to the exact type of space development that this nation needs. In the early 60's NASA didn't lose any face by choosing to re-purpose ICBMs for the Mercury and Gemini programs. Instead, out of necessity, NASA it's rocket building teams on the Saturn series of rockets. It was the practical decision then and it is the practical decision to re-purpose existing vehicles now for LEO access.

    If NASA wants to build a launcher (and whether they should be building any is a very debatable) then they should be concentrating exclusively on the Ares V/VI which actually goes somewhere and does something that commercial space companies may not be able to do economically today.

  15. Re:Why the Ares I? -- Uhh, payload? by Phairdon · · Score: 5, Informative

    Did you look at how much payload each rocket can take to orbit before you made this post? Look at the payload capacity to GTO (not LEO)

    Let me list the estimated maximum payloads since you did not:
    Delta IV: 20,000 pounds or so
    Atlas V: 18,000 pounds or so
    SpaceX Falcon 9: 27,000 pounds or so
    Ares I: 50,000 pounds or so

    See the difference? Ares I is also rated for man-flight, which just makes everything much more complicated.

    The article is from a florida newspaper. Of course florida newspapers are going to print doom stories because they don't want to lose Shuttle business. Losing business happens.

  16. Re:Did we really make it to the moon? by poobie · · Score: 4, Informative

    err, the S-1C was a Kerosene/LOX burner, and the upper stages were hydrogen/LOX. The Titan, which was obviously not part of Apollo, used some really toxic hypergolic fuels, but Apollo was relatively clean. I'm sure the spacecraft itself had plenty of toxic crap in it, but the booster was relatively safe.

  17. Re:I'm outraged? by tbfee · · Score: 4, Informative

    It's much more complicated than your home furnishing project. NASA can't simply apply funds from elsewhere it its budget; that money is already spoken for, and appropriated by Congress for other projects. In other words, there is no way, within the law, to take money from another project to fix this problem; additional funding or reprogramming actions are required, both of which take time. Even in Washington, $80M is a big issue. As it should be.

    --
    It's not the heat, it's the futility.
  18. Re:Just wait by AKAImBatman · · Score: 4, Informative

    The Ares V will even put the Sat V to shame.

    Ares V Stats
    ============
    Height: 116 m
    Diameter: 10 m + 3.7 m(2x)
    Payload to LEO: 130,000 kg (does not appear to be corrected after addition of sixth engine)
    Payload to GEO: 71,100 kg
     
    Saturn V Stats
    ==============
    Height: 110.6 m
    Diameter: 10.1 m
    Payload to LEO: 118,000 kg
    Payload to GEO: 47,000 kg

    The Ares V is going to be the large booster we SHOULD have built after the Saturn V. It's late, but it's finally coming. :-)

  19. Re:Did we really make it to the moon? by willith · · Score: 5, Insightful

    Damn it, I *JUST YESTERDAY* posted to correct this fallacy. When will the Internet learn?

    The blueprints for everything, down to the last nut and bolt, are on file at MSFC. Source.

    Further, rebuilding a Saturn from them won't work. You can't get the parts made any more, nor would you want to. You can't duplicate IBM's work and make another Instrument Unit--two tons of 1960s-vintage analog computers and gyroscopes, including equipment designed to determine the rocket's launch azimuth based on star sightings, not GPS like we'd use today. Then there's all the other analog and early digital equipment that's integral to the design. Remember, it's not just a giant fuel tank and some engines--it's a launch vehicle. It's got a flight manual, and it's designed to be used in conjunction with an Apollo command and service module pair flying it.

    Re-design the rocket to use new technology? By the time you've de-Apollo'd Saturn, you've made a whole new launch vehicle. Which is exactly what Ares is.

    The Saturn V is an awesome piece of technology, yes. An awesome piece of 1960s technology. Rebuilding it today would not work, period, no matter how cool it might be.

  20. Re:Just wait by AKAImBatman · · Score: 4, Interesting

    FYI, I found updated numbers for the six engine Ares V on NASA's site here:

    http://www.nasa.gov/mission_pages/constellation/ares/aresV/index.html

    The correct LEO figure is stated here:

    The versatile, heavy-lifting Ares V is a two-stage, vertically stacked launch vehicle. It can carry nearly 414,000 pounds (188 metric tons) to low-Earth orbit. When working together with the Ares I crew launch vehicle to launch payloads into Earth orbit, Ares V can send nearly 157,000 pounds (71 metric tons) to the moon.

  21. I am a Rocket Scientist by tweak13 · · Score: 4, Insightful

    They're screwed. MacGyver himself couldn't keep this project on schedule with all the duct tape, rubber bands and paperclips in the world.

    The problem is, this project is massive. It was obvious from the beginning that their time estimates were basically based on everything working perfectly the first time and optimization studies showing that they'd already picked the most efficient design. There are always going to be problems, and the bigger the project the more you're going to have.

    If they're serious about replacing the shuttle with only a couple years of downtime, they should already be gearing up to test the system as a whole. I'm not personally involved in the project, but it doesn't even look like they're ready to test big pieces yet. Maybe 2020 is a more reasonable date to actually begin flights.

    1. Re:I am a Rocket Scientist by benjackson520 · · Score: 5, Informative

      If they're serious about replacing the shuttle with only a couple years of downtime, they should already be gearing up to test the system as a whole. I'm not personally involved in the project, but it doesn't even look like they're ready to test big pieces yet. Maybe 2020 is a more reasonable date to actually begin flights.

      Disclaimer: I'm a NASA employee at Stennis Space Center, programmer not rocket scientist. The first round of testing on the powerpacks for the new J-2X engines was last month, second round is scheduled for early 2009. That's not the fully assembled engine assemblies, but it's progress.

  22. Re:don't forget zip-ties by ArsonSmith · · Score: 4, Funny

    My tool box has two items. Duct tape and WD-40.

    If it moves and it's not suppose to Duct Tape it.
    If it doesn't move and it is suppose to WD-40 it.

    --
    Paying taxes to buy civilization is like paying a hooker to buy love.
  23. Re:Just wait by AJWM · · Score: 4, Insightful

    The difference is that the Saturn V stats reflect real performance, the Ares V figures are still hypothetical. Shuttle never got much more than about 80% of its originally advertised payload capacity.

    And of course, Saturn V is 45 year old technology. Just replacing the Instrument Unit (guidance system) with modern avionics would add about 2000 kg to the payload.

    --
    -- Alastair