Aerospace manufacturing is a high technology industry that produces aircraft, guided missiles, space vehicles, aircraft engines.Read more ...
The Space Shuttle was a manned orbital rocket and spacecraft system operated by NASA on 135 missions from 1981 to 2011. The system combined rocket launch, orbital spacecraft, and re-entry spaceplane with modular add-ons. Major missions included launching numerous satellites and interplanetary probes, conducting space science experiments, and the servicing and construction of space stations. A major international contribution was the Spacelab payload suite, from the ESA.
The Space Shuttle was a partially reusable launch system and orbital spacecraft operated by the U.S. National Aeronautics and Space Administration (NASA) for human spaceflight missions from 1981 to 2011. The system combined rocket launch, orbital spacecraft, and re-entry spaceplane with modular add-ons. The first of four orbital test flights occurred in 1981 leading to operational flights beginning in 1982, all launched from the Kennedy Space Center, Florida. The system was retired from service in 2011 after 135 missions; on July 8, 2011, with Space Shuttle Atlantis performing that 135th launch - the final launch of the three-decade shuttle program. The program ended after Atlantis landed at the Kennedy Space Center on July 21, 2011. Major missions included launching numerous satellites and interplanetary probes, conducting space science experiments, and servicing and construction of space stations. Enterprise was a prototype orbiter used for atmospheric testing during development in the 1970s and lacked engines and heat shield. Five space-worthy orbiters were built—two were destroyed in accidents and the others have been retired.
It was used for orbital space missions by NASA, the U.S. Department of Defense, the European Space Agency, Japan, and Germany. The United States funded Space Transportation System (STS) development and shuttle operations except for Spacelab D1 and D2 — sponsored by West Germany and reunified Germany respectively. In addition, SL-J was partially funded by Japan.
At launch, it consisted of the "stack", including a dark orange-coloured external tank (ET); two white, slender Solid Rocket Boosters (SRBs); and the Orbiter Vehicle (OV), which contained the crew and payload. Some payloads were launched into higher orbits with either of two different booster stages developed for the STS (single-stage Payload Assist Module or two-stage Inertial Upper Stage). The Space Shuttle was stacked in the Vehicle Assembly Building and the stack mounted on a mobile launch platform held down by four explosive bolts on each SRB which are detonated at launch.
The shuttle stack launched vertically like a conventional rocket. It lifted off under the power of its two SRBs and three main engines, which were fueled by liquid hydrogen and liquid oxygen from the external tank. The Space Shuttle had a two-stage ascent. The SRBs provided additional thrust during liftoff and first-stage flight. About two minutes after liftoff, explosive bolts were fired, releasing the SRBs, which then parachuted into the ocean, to be retrieved by ships for refurbishment and reuse. The shuttle orbiter and external tank continued to ascend on an increasingly horizontal flight path under power from its main engines. Upon reaching 17,500 mph (7.8 km/s), necessary for low Earth orbit, the main engines are shut down. The external tank was then jettisoned to burn up in the atmosphere. After jettisoning the external tank, the orbital manoeuvring system (OMS) engines were used to adjust the orbit.
The orbiter carried people and payload such as satellites or space station parts into low Earth orbit, into the Earth's upper atmosphere or thermosphere. Usually, five to seven crew members rode in the orbiter. Two crew members, the commander and pilot, were sufficient for a minimal flight, as in the first four "test" flights, STS-1 through STS-4. The typical payload capacity was about 22,700 kilogrammes (50,000 lb) but could be increased depending on the choice of the launch configuration. The orbiter carried its payload in a large cargo bay with doors that opened along the length of its top, a feature which made the Space Shuttle unique among spacecraft. This feature made possible the deployment of large satellites such as the Hubble Space Telescope, and also the capture and return of large payloads back to Earth.
When the orbiter's space mission was complete, it fired its OMS thrusters to drop out of orbit and re-enter the lower atmosphere. During the descent, the orbiter passed through different layers of the atmosphere and decelerates from hypersonic speed primarily by aerobraking. In the lower atmosphere and landing phase, it was more like a glider but with reaction control system (RCS) thrusters and fly-by wire-controlled hydraulically-actuated flight surfaces controlling its descent. It landed on a long runway as a spaceplane. The aerodynamic shape was a compromise between the demands of radically different speeds and air pressures during re-entry, hypersonic flight, and subsonic atmospheric flight. As a result, the orbiter had a relatively high sink rate at low altitudes, and it transitioned during re-entry from using RCS thrusters at very high altitudes to flight surfaces in the lower atmosphere.
The formal design of what became the Space Shuttle began with "Phase A" contract design studies issued in the late 1960s. However, conceptualization began two decades earlier, before the Apollo program of the 1960s. One of the places the concept of a spacecraft returning from space to a horizontal landing originated was within NACA, in 1954, in the form of an aeronautics research experiment, later named the X-15. The NACA proposal was submitted by Walter Dornberger.
In 1958, the X-15 concept further developed into a proposal to launch an X-15 into space, and another X-series spaceplane proposal called the X-20, which was not constructed, as well as a variety of aerospace plane concepts and studies. Neil Armstrong was selected to pilot both the X-15 and the X-20. Though the X-20 was not built, another spaceplane similar to the X-20 was built several years later and delivered to NASA in January 1966 called the HL-10 ("HL" indicated "horizontal landing").
In the mid-1960s, the US Air Force conducted a series of classified studies on next-generation space transportation systems and concluded that semi-reusable designs were the cheapest choice. It proposed a development program with an immediate start on a "Class I" vehicle with expendable boosters, followed by the slower development of a "Class II" semi-reusable design and perhaps a "Class III" fully reusable design later. In 1967, George Mueller held a one-day symposium at NASA headquarters to study the options. Eighty people attended and presented a wide variety of designs, including earlier Air Force designs as the Dyna-Soar (X-20).
In 1968, NASA officially began work on what was then known as the Integrated Launch and Re-entry Vehicle (ILRV). At the same time, NASA held a separate Space Shuttle Main Engine (SSME) competition. NASA offices in Houston and Huntsville jointly issued a Request for Proposal (RFP) for ILRV studies to design a spacecraft that could deliver a payload to orbit but also re-enter the atmosphere and fly back to Earth. For example, one of the responses was for a two-stage design, featuring a large booster and a small orbiter, called the DC-3, one of the several Phase A shuttle designs. After the aforementioned "Phase A" studies, B, C, and D phases progressively evaluated in-depth designs up to 1972. In the final design, the bottom stage was recoverable solid rocket boosters, and the top stage used an expendable external tank.
In 1969, President Richard Nixon decided to support proceeding with Space Shuttle development. A series of development programs and analysis refined the basic design, prior to full development and testing. In August 1973, the X-24B proved that an unpowered spaceplane could re-enter Earth's atmosphere for a horizontal landing.
Across the Atlantic, European ministers met in Belgium in 1973 to authorise Western Europe's manned orbital project and its main contribution to Space Shuttle — the Spacelab program. Spacelab would provide a multi-disciplinary orbital space laboratory and additional space equipment for the Shuttle.
The Space Shuttle was the first operational orbital spacecraft designed for reuse. It carried different payloads to low Earth orbit, provided crew rotation for the International Space Station (ISS) and performed servicing missions. The orbiter could also recover satellites and other payloads from orbit and return them to Earth. Each Shuttle was designed for a projected lifespan of 100 launches or ten years of operational life, although this was later extended. The person in charge of designing the STS was Maxime Faget, who had also overseen the Mercury, Gemini, and Apollo spacecraft designs. The crucial factor in the size and shape of the Shuttle Orbiter was the requirement that it be able to accommodate the largest planned commercial and military satellites, and have the cross-range recovery range to meet the requirement for classified USAF missions for a once-around abort from a launch to a polar orbit. Factors involved in opting for solid rockets and an expendable fuel tank included the desire of the Pentagon to obtain a high-capacity payload vehicle for satellite deployment, and the desire of the Nixon administration to reduce the costs of space exploration by developing a spacecraft with reusable components.
Each Space Shuttle is a reusable launch system that is composed of three main assemblies: the reusable Orbiter Vehicle (OV), the expendable external tank (ET), and the two reusable solid rocket boosters(SRBs). Only the orbiter entered orbit shortly after the tank and boosters are jettisoned. The vehicle was launched vertically like a conventional rocket, and the orbiter glided to a horizontal landing like an aeroplane, after which it was refurbished for reuse. The SRBs parachuted to splashdown in the ocean where they were towed back to shore and refurbished for later shuttle missions.
Five space-worthy orbiters were built: Columbia (OV-102), Challenger (OV-099), Discovery (OV-103), Atlantis (OV-104), and Endeavour (OV-105). An additional craft, Enterprise (OV-101), was not built for orbital space flight and was used only for testing gliding and landing. Enterprise was originally intended to be made fully space-worthy after use for the approach and landing test (ALT) program, but it was found more economical to upgrade the structural test article STA-099 into orbiter Challenger (OV-099). Challenger disintegrated 73 seconds after launch in 1986, and Endeavour was built as a replacement for Challenger from structural spare components. Columbia broke apart during re-entry in 2003. Building Space Shuttle Endeavour cost about US$1.7 billion. One Space Shuttle launch costs around $450 million.
Roger A. Pielke, Jr. has estimated that the Space Shuttle program has cost about US$170 billion (2008 dollars) through early 2008. This works out to an average cost per flight of about US$1.5 billion. However, two missions were paid for by Germany, Spacelab D1 and D2 (D for Deutschland) with a payload control centre in Oberpfaffenhofen, Germany. D1 was the first time that control of a manned STS mission payload was not in U.S. hands.
At times, the orbiter itself was referred to as the Space Shuttle. Technically, this was a slight misnomer, as the actual "Space Transportation System" (Space Shuttle) was the combination of the orbiter, the external tank, and the two solid rocket boosters. Combined, these were referred to as the "stack"; the components were assembled in the Vehicle Assembly Building, originally built to assemble the Apollo Saturn V rocket.
Responsibility for the shuttle components was spread among multiple NASA field centres. The Kennedy Space Center was responsible for launch, landing and turnaround operations for equatorial orbits (the only orbit profile actually used in the program), the US Air Force at the Vandenberg Air Force Base was responsible for launch, landing and turnaround operations for polar orbits (though this was never used), theJohnson Space Center served as the central point for all shuttle operations, the Marshall Space Flight Center was responsible for the main engines, external tank, and solid rocket boosters, the John C. Stennis Space Center handled main engine testing, and the Goddard Space Flight Center managed the global tracking network.
The orbiter resembles a conventional aircraft, with double-delta wings, swept 81° at the inner leading edge and 45° at the outer leading edge. Its vertical stabiliser's leading edge is swept back at a 50° angle. The four elevons mounted at the trailing edge of the wings, and the rudder/speed brake, attached at the trailing edge of the stabiliser, with the body flap, controlled the orbiter during descent and landing.
The orbiter's payload bay measures 15 by 60 feet (4.6 by 18 m), comprising most of the fuselage. Information declassified in 2011 showed that the payload bay was designed specifically to accommodate the KH-9 HEXAGON spy satellite operated by the National Reconnaissance Office. Two mostly symmetrical lengthwise payload bay doors hinged on either side of the bay comprise its entire top. Payloads are generally loaded horizontally into the bay while the orbiter is oriented vertically on the launch pad and unloaded vertically in the near-weightless orbital environment by the orbiter's robotic remote manipulator arm (under astronaut control), EVA astronauts, or under the payloads' own power (as for satellites attached to a rocket "upper stage" for deployment.)
Three Space Shuttle main engines (SSMEs) are mounted on the orbiter's aft fuselage in a triangular pattern. The engine nozzles can swivel 10.5 degrees up and down, and 8.5 degrees from side to side during ascent to change the direction of their thrust to steer the shuttle. The orbiter structure is made primarily from aluminium alloy, although the engine structure is made primarily from titanium alloy.
The space-capable orbiters built were OV-102 Columbia, OV-099 Challenger, OV-103 Discovery, OV-104 Atlantis, and OV-105 Endeavour.