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A Look At Orion's Launch Abort System
An anonymous reader writes: With the construction of Orion, NASA's new manned spacecraft, comes the creation of a new Launch Abort System — the part of the vehicle that will get future astronauts back to Earth safely if there's a problem at launch. The Planetary Society's Jason Davis describes it: "When Orion reaches the apex of its abort flight, it is allowed to make its 180-degree flip. The capsule of astronauts, who have already realized they will not go to space today, experience a brief moment of weightlessness before the capsule starts falling back to Earth, heat shield down. The jettison motor fires, pulling the LAS away from Orion. ... Orion, meanwhile, sheds its Forward Bay Cover, a ring at the top of the capsule protecting the parachutes. Two drogue chutes deploy, stabilizing the wobbling capsule. The drogues pull out Orion's three main chutes, no doubt eliciting a sigh of relief from the spacecraft's occupants."
Isn't Orion a space craft being made by the crooks at Boeing, Lockheed and the other losers who rape the shit out of tax payers, intentionally underbid projects and run decades and billions over budget and laugh at us?
NASA should not be allowed to commission their own spacecraft since the laws currently in place force them to choose contractors like those crooks to build their space craft and when was the last time any of them actually built anything that wasn't a royal heap of shit?
If only the decision was that simple... Sadly, it wasn't.
First there were performance issues; The solid motors need to match to within 5% of each other - which proved essentially impossible to achieve with a monolithic grain as the propellant tended to stratify during the extended pour and the extended curing time. The solid motors needed to have consistent and predictable performance during the burn - which was almost impossible to achieve due to the aforementioned stratification problems. Both problems were also made worse because they couldn't figure out how to safely mix and pour the grains for both boosters in a single batch. Segmented grains, which could be poured in LH and RH segments from a single (smaller) batch suffered from none of these problems.
Next, there's storage and handling problems. The larger the grain, the heavier it is, and the harder it is to prevent it from flowing and deforming under it's own weight. Equally, since the large grains have to be cast upside down they have to be rotated rightside up - and nobody knew how to do that with large monolithic grains. A flex of as little as a couple of millimeters could crack the grain or lead to delamination. Also, segments could be stored individually, reducing fire and explosion risk.
Inspecting the grains with the technology of the time was also several orders of magnitude harder for a large monolithic grain.
Lastly, while there was a only a limited base of flight experience with large segmented grains (via the Titan IIIC)... there was no flight experience with large monolithic grains.
tl;dr version - there were a lot fewer known unknowns with segmented solids than with monolithic solids. A number of the known unknowns for monolithic grains were either outright show stoppers or could result in ruinously expensive R&D programs to discover if a solution was even possible. The known unknowns for segmented grains were all issues of scaling from existing experience.