Space Shuttle
The Space Shuttle is a retired, partially reusable low Earth orbital spacecraft system operated from 1981 to 2011 by the U.S. National Aeronautics and Space Administration as part of the Space Shuttle program. Its official program name was the Space Transportation System, taken from the 1969 plan led by U.S. vice president Spiro Agnew for a system of reusable spacecraft where it was the only item funded for development.
The first of four orbital test flights occurred in 1981, leading to operational flights beginning in 1982. Five complete Space Shuttle orbiter vehicles were built and flown on a total of 135 missions from 1981 to 2011. They launched from the Kennedy Space Center in Florida. Operational missions launched numerous satellites, interplanetary probes, and the Hubble Space Telescope, conducted science experiments in orbit, participated in the Shuttle-Mir program with Russia, and participated in the construction and servicing of the International Space Station. The Space Shuttle fleet's total mission time was 1,323 days.
Space Shuttle components include the Orbiter Vehicle with three clustered Rocketdyne RS-25 main engines, a pair of recoverable solid rocket boosters, and the expendable external tank containing liquid hydrogen and liquid oxygen. The Space Shuttle was launched vertically, like a conventional rocket, with the two SRBs operating in parallel with the orbiter's three main engines, which were fueled from the ET. The SRBs were jettisoned before the vehicle reached orbit, while the main engines continued to operate, and the ET was jettisoned after main engine cutoff and just before orbit insertion, which used the orbiter's two Orbital Maneuvering System engines. At the conclusion of the mission, the orbiter fired its OMS to deorbit and reenter the atmosphere. The orbiter was protected during reentry by its thermal protection system tiles, and it glided as a spaceplane to a runway landing, usually to the Shuttle Landing Facility at KSC, Florida, or to Rogers Dry Lake in Edwards Air Force Base, California. If the landing occurred at Edwards, the orbiter was flown back to the KSC atop the Shuttle Carrier Aircraft, a specially modified Boeing 747 designed to carry the shuttle above it.
The first orbiter, Enterprise, was built in 1976 and used in Approach and Landing Tests, but had no orbital capability. Four fully operational orbiters were initially built: Columbia, Challenger, Discovery, and Atlantis. Of these, two were lost in mission accidents: Challenger in 1986 and Columbia in 2003, with a total of 14 astronauts killed. A fifth operational orbiter, Endeavour, was built in 1991 to replace Challenger. The three surviving operational vehicles were retired from service following Atlantiss final flight on July 21, 2011. The U.S. relied on the Russian Soyuz spacecraft to transport astronauts to the ISS from the last Shuttle flight until the launch of the Crew Dragon Demo-2 mission in May 2020.
Design and development
Historical background
In the late 1930s, the German government launched the "Amerikabomber" project, and Eugen Sänger's idea, together with mathematician Irene Bredt, was a winged rocket called the Silbervogel. During the 1950s, the United States Air Force proposed using a reusable piloted glider to perform military operations such as reconnaissance, satellite attack, and air-to-ground weapons employment. In the late 1950s, the Air Force began developing the partially reusable X-20 Dyna-Soar. The Air Force collaborated with NASA on the Dyna-Soar and began training six pilots in June 1961. The rising costs of development and the prioritization of Project Gemini led to the cancellation of the Dyna-Soar program in December 1963. In addition to the Dyna-Soar, the Air Force had conducted a study in 1957 to test the feasibility of reusable boosters. This became the basis for the aerospaceplane, a fully reusable spacecraft that was never developed beyond the initial design phase in 1962–1963.Beginning in the early 1950s, NASA and the Air Force collaborated on developing lifting bodies to test aircraft that primarily generated lift from their fuselages instead of wings, and tested the NASA M2-F1, Northrop M2-F2, Northrop M2-F3, Northrop HL-10, Martin Marietta X-24A, and the Martin Marietta X-24B. The program tested aerodynamic characteristics that would later be incorporated in design of the Space Shuttle, including unpowered landing from a high altitude and speed.
Design process
On September 24, 1966, as the Apollo space program neared its design completion, NASA and the Air Force released a joint study concluding that a new vehicle was required to satisfy their respective future demands and that a partially reusable system would be the most cost-effective solution. The head of the NASA Office of Manned Space Flight, George Mueller, announced the plan for a reusable shuttle on August 10, 1968. NASA issued a request for proposal for designs of the Integral Launch and Reentry Vehicle on October 30, 1968. Rather than award a contract based upon initial proposals, NASA announced a phased approach for the Space Shuttle contracting and development; Phase A was a request for studies completed by competing aerospace companies, Phase B was a competition between two contractors for a specific contract, Phase C involved designing the details of the spacecraft components, and Phase D was the production of the spacecraft.In December 1968, NASA created the Space Shuttle Task Group to determine the optimal design for a reusable spacecraft, and issued study contracts to General Dynamics, Lockheed, McDonnell Douglas, and North American Rockwell. In July 1969, the Space Shuttle Task Group issued a report that determined the Shuttle would support short-duration crewed missions and space station, as well as the capabilities to launch, service, and retrieve satellites. The report also created three classes of a future reusable shuttle: Class I would have a reusable orbiter mounted on expendable boosters, Class II would use multiple expendable rocket engines and a single propellant tank, and Class III would have both a reusable orbiter and a reusable booster. In September 1969, the Space Task Group, under the leadership of U.S. vice president Spiro Agnew, issued a report calling for the development of a space shuttle to bring people and cargo to low Earth orbit, as well as a space tug for transfers between orbits and the Moon, and a reusable nuclear upper stage for deep space travel.
After the release of the Space Shuttle Task Group report, many aerospace engineers favored the Class III, fully reusable design because of perceived savings in hardware costs. Max Faget, a NASA engineer who had worked to design the Mercury capsule, patented a design for a two-stage fully recoverable system with a straight-winged orbiter mounted on a larger straight-winged booster. The Air Force Flight Dynamics Laboratory argued that a straight-wing design would not be able to withstand the high thermal and aerodynamic stresses during reentry, and would not provide the required cross-range capability. Additionally, the Air Force required a larger payload capacity than Faget's design allowed. In January 1971, NASA and Air Force leadership decided that a reusable delta-wing orbiter mounted on an expendable propellant tank would be the optimal design for the Space Shuttle.
After they established the need for a reusable, heavy-lift spacecraft, NASA and the Air Force determined the design requirements of their respective services. The Air Force expected to use the Space Shuttle to launch large satellites, and required it to be capable of lifting to an eastward LEO or into a polar orbit. The satellite designs also required that the Space Shuttle have a payload bay. NASA evaluated the F-1 and J-2 engines from the Saturn rockets, and determined that they were insufficient for the requirements of the Space Shuttle; in July 1971, it issued a contract to Rocketdyne to begin development on the RS-25 engine.
NASA reviewed 29 potential designs for the Space Shuttle and determined that a design with two side boosters should be used, and the boosters should be reusable to reduce costs. NASA and the Air Force elected to use solid-propellant boosters because of the lower costs and the ease of refurbishing them for reuse after they landed in the ocean. In January 1972, President Richard Nixon approved the Shuttle, and NASA decided on its final design in March. The development of the Space Shuttle Main Engine remained the responsibility of Rocketdyne, and the contract was issued in July 1971, and updated SSME specifications were submitted to Rocketdyne that April. The following August, NASA awarded the contract to build the orbiter to North American Rockwell, which had by then constructed a full-scale mock-up, later named Inspiration. In August 1973, NASA awarded the external tank contract to Martin Marietta, and in November the solid-rocket booster contract to Morton Thiokol.
Development
On June 4, 1974, Rockwell began construction on the first orbiter, OV-101, dubbed Constitution, later to be renamed Enterprise. Enterprise was designed as a test vehicle, and did not include engines or heat shielding. Construction was completed on September 17, 1976, and Enterprise was moved to the Edwards Air Force Base to begin testing. Rockwell constructed the Main Propulsion Test Article -098, which was a structural truss mounted to the ET with three RS-25 engines attached. It was tested at the National Space Technology Laboratory to ensure that the engines could safely run through the launch profile. Rockwell conducted mechanical and thermal stress tests on Structural Test Article -099 to determine the effects of aerodynamic and thermal stresses during launch and reentry.The beginning of the development of the RS-25 Space Shuttle Main Engine was delayed for nine months while Pratt & Whitney challenged the contract that had been issued to Rocketdyne. The first engine was completed in March 1975, after issues with developing the first throttleable, reusable engine. During engine testing, the RS-25 experienced multiple nozzle failures, as well as broken turbine blades. Despite the problems during testing, NASA ordered the nine RS-25 engines needed for its three orbiters under construction in May 1978.
NASA experienced significant delays in the development of the Space Shuttle's thermal protection system. Previous NASA spacecraft had used ablative heat shields, but those could not be reused. NASA chose to use ceramic tiles for thermal protection, as the shuttle could then be constructed of lightweight aluminum, and the tiles could be individually replaced as needed. Construction began on Columbia on March 27, 1975, and it was delivered to the KSC on March 25, 1979. At the time of its arrival at the KSC, Columbia still had 6,000 of its 30,000 tiles remaining to be installed. However, many of the tiles that had been originally installed had to be replaced, requiring two years of installation before Columbia could fly.
On January 5, 1979, NASA commissioned a second orbiter. Later that month, Rockwell began converting STA-099 to OV-099, later named Challenger. On January 29, 1979, NASA ordered two additional orbiters, OV-103 and OV-104, which were named Discovery and Atlantis. Construction of OV-105, later named Endeavour, began in February 1982, but NASA decided to limit the Space Shuttle fleet to four orbiters in 1983. After the loss of Challenger, NASA resumed production of Endeavour in September 1987.