Space Launch System (SLS) Booster Element Support
DCI supports the MSFC Space Launch System Booster Element in
multiple areas relative to the application and modification of heritage Shuttle
Space Transportation System booster hardware for the SLS program.
- Primary Structure and Component Development and
Qualification Test Support
Structural test load case selection and on-site
test support was provided for the forward skirt structural test series. This
testing was performed to determine the structural capability of the heritage
Shuttle booster forward skirt and whether the hardware could sustain the SLS
loads. Forward skirt factor of safety
methodology was also worked.
Avionics and Flight Separation System Battery
development testing was supported to verify design concepts to increase the
battery’s ability to withstand increased random vibration environments for SLS.
Unique methods were developed to investigate battery problem areas and verify
design modifications. Additional battery component development testing was
supported to check the design modifications prior to full battery testing.
Load derivation and hardware production issues
are being supported for the development of the SLS modified forward separation
bolt. Improvements to the heritage forward
separation bolt data acquisition system have been worked. Test system checkout
and forward separation bolt build procedures are being reviewed to ensure the
modified forward separation bolt will be able to meet SLS requirements. This is
one area where new Booster hardware is being manufactured.
Booster test and design requirements for the
EPDM strut covers are being supported. Design requirements for SLS require
modifications to the EPDM strut covers. Testing is required to verify the
design requirements to ensure appropriate modifications are made to the
Booster Integrated Product Teams (IPTs) working
various hardware issues that arise as heritage hardware is transitioned to SLS
are being supported.
Level II Booster Element loads generated from
the integrated vehicle design analysis cycles documented in the Booster Loads
Databook are reviewed.
Updates to Booster data requested from the
integrated vehicle loads analysis are checked and worked with Level II loads
Booster Element developed random vibration
component loads and methodologies are reviewed.
- Booster Developed Finite Element Models and
Booster Element dynamic math models prepared for
the integrated vehicle coupled loads analysis are checked
Booster segment models for stacking analyses
were prepared and checked
Operational loads during vehicle assembly are
developed. An example are the loads required to pull the boosters apart prior
to mating Core with the boosters.
Analysis performed to determine loads for
forward attach components are reviewed
Design issues for the aft attach components are
worked. The SLS vehicle has expanded design requirements for the aft attach
compared to Shuttle. Strut articulation, joint freeplay, and EPDM strut cover
issues are being supported.
Loads and stability analysis for the Booster
interface with the Mobile Launcher Vehicle Support Posts are performed.