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ga('create', 'UA-58349124-1', 'auto'); ga('send', 'pageview'); </script>  </head> <body> <div id="wrapper"> <div id="title"> <a class="home" href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/"></a> <h1>Spaceflight Insider</h1> </div> <input type="checkbox" id="nav-trigger" class="nav-trigger"/> <label for="nav-trigger"></label> <ul id="nav"> <li class="toggle disabled"><a href="#" class="brightness" title="Toggle Brightness"><span><span></span></span></a></li> <input type="checkbox" id="search-trigger" class="search-trigger"/> <label for="search-trigger"></label> <li class="search"> <form role="search" method="get" action="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/"> <input type="search" placeholder="Search" name="s"> <button type="submit">Search</button> </form> <a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/search">Search</a> </li> <li><a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/">Home</a></li> <li><a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/archive">Archive</a></li> <li><a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/gallery">Gallery</a></li> <li><a class="feature" href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/launch-schedule">Launch Schedule</a></li> <li><a class="feature" href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/mission-monitor">Mission Monitor</a></li> <li><a class="feature" href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/hangar">The Hangar</a></li> <ul class="social"> <li><a class="facebook" href="https://web.archive.org/web/20200725065447/http://www.facebook.com/pages/The-Spaceflight-Group/254774621252230" title="Add us on Facebook"> </a></li> <li><a class="twitter" href="https://web.archive.org/web/20200725065447/http://www.twitter.com/spaceflightins" title="Follow us on Twitter"> </a></li> <li><a class="youtube" href="https://web.archive.org/web/20200725065447/http://www.youtube.com/spaceflightgroup" title="YouTube Channel"> </a></li> </ul> </ul> <div id="content-wrapper" class=""> <div id="banner"> <div class="responsive"> <div><ul style="margin: 0; padding: 0;" class="ml-adverts banner"><li style="margin: 0; padding: 0;" class="ml-adverts-119831"><script async src="//web.archive.org/web/20200725065447js_/https://pagead2.googlesyndication.com/pagead/js/adsbygoogle.js"></script>  <ins class="adsbygoogle" style="display:block" data-ad-client="ca-pub-3700447070904041" data-ad-slot="3615014613" data-ad-format="auto" data-full-width-responsive="true"></ins> <script> (adsbygoogle = window.adsbygoogle || []).push({}); </script></li></ul></div> </div> </div> <div id="content"> <div class="sfi-container post" id="post-48102"> <h1><span><span><span>Four to five: Engineer details changes made to SLS booster</span></span></span></h1>  <div class="news-post-info"> <div class="author">Jason Rhian</div> <div class="date">January 10th, 2016</div> </div><div class="shareaholic-canvas" data-app="share_buttons" data-title="Four to five: Engineer details changes made to SLS booster" data-link="https://www.spaceflightinsider.com/missions/human-spaceflight/four-five-engineer-details-shuttles-booster-will-used-sls/" data-summary="KENNEDY SPACE CENTER, Fla. — It has been more than forty years since humanity broke free of the bonds of Earth's gravity for points beyond. NASA is working to use existing "legacy" systems – such as the Space Shuttle Program. SFI spoke with one engineer who is working to make this happen." data-app-id="28397427" data-app-id-name="post_above_content"></div><div id="attachment_49446" style="width: 1320px" class="wp-caption aligncenter"><a href="https://web.archive.org/web/20200725065447/http://www.spaceflightinsider.com/wp-content/uploads/2016/01/871-orbital_atk_qm_1-mark_usciak.jpg" target="_blank"><img aria-describedby="caption-attachment-49446" class="wp-image-49446 size-full" src="https://web.archive.org/web/20200725065447im_/http://www.spaceflightinsider.com/wp-content/uploads/2016/01/871-orbital_atk_qm_1-mark_usciak.jpg" alt="Orbital ATK NASA Space Launch System five segment solid rocket booster Promontory Utah photo credit Mark Usciak SpaceFlight Insider" width="1310" height="376" srcset="https://web.archive.org/web/20200725065447im_/https://www.spaceflightinsider.com/wp-content/uploads/2016/01/871-orbital_atk_qm_1-mark_usciak.jpg 1310w, https://web.archive.org/web/20200725065447im_/https://www.spaceflightinsider.com/wp-content/uploads/2016/01/871-orbital_atk_qm_1-mark_usciak-300x86.jpg 300w, https://web.archive.org/web/20200725065447im_/https://www.spaceflightinsider.com/wp-content/uploads/2016/01/871-orbital_atk_qm_1-mark_usciak-768x220.jpg 768w, https://web.archive.org/web/20200725065447im_/https://www.spaceflightinsider.com/wp-content/uploads/2016/01/871-orbital_atk_qm_1-mark_usciak-655x188.jpg 655w, https://web.archive.org/web/20200725065447im_/https://www.spaceflightinsider.com/wp-content/uploads/2016/01/871-orbital_atk_qm_1-mark_usciak-1280x367.jpg 1280w" sizes="(max-width: 1310px) 100vw, 1310px"/></a><p id="caption-attachment-49446" class="wp-caption-text">Orbital ATK’s Jessica Widrick is working to have two of the company’s five-segment solid rocket boosters hoist NASA’s new super heavy-lift Space Launch System aloft. Photo Credit: Mark Usciak / SpaceFlight Insider</p></div> <p>KENNEDY SPACE CENTER, Fla. — It has been more than forty years since humanity broke free of the bonds of Earth’s gravitational sphere of influence and headed out for points beyond. NASA is now working to correct that, to alter its course. The economic climate for a full renewal was never in the offing and the agency and its itinerant contractors found other ways to use existing “legacy” systems – such as the Space Shuttle Program.<span id="more-48102"></span></p> <div id="attachment_49442" style="width: 215px" class="wp-caption alignright"><a href="https://web.archive.org/web/20200725065447/http://www.spaceflightinsider.com/wp-content/uploads/2016/01/184347-11.jpg" target="_blank"><img aria-describedby="caption-attachment-49442" class="wp-image-49442" src="https://web.archive.org/web/20200725065447im_/http://www.spaceflightinsider.com/wp-content/uploads/2016/01/184347-11-395x655.jpg" alt="Jessica Widrick, joints and seals design engineer at Orbital ATK, inspects igniter bolts and seals after the static test of the first five-segment qualification motor for NASA’s Space Launch System. Photo Credit Orbital ATK posted on SpaceFlight Insider" width="205" height="340" srcset="https://web.archive.org/web/20200725065447im_/https://www.spaceflightinsider.com/wp-content/uploads/2016/01/184347-11-395x655.jpg 395w, https://web.archive.org/web/20200725065447im_/https://www.spaceflightinsider.com/wp-content/uploads/2016/01/184347-11-181x300.jpg 181w, https://web.archive.org/web/20200725065447im_/https://www.spaceflightinsider.com/wp-content/uploads/2016/01/184347-11-768x1272.jpg 768w, https://web.archive.org/web/20200725065447im_/https://www.spaceflightinsider.com/wp-content/uploads/2016/01/184347-11.jpg 966w" sizes="(max-width: 205px) 100vw, 205px"/></a><p id="caption-attachment-49442" class="wp-caption-text"><span style="font-size: 12px;">Jessica Widrick, joints and seals design engineer at Orbital ATK, inspects igniter bolts and seals after the static test of the first five-segment qualification motor for NASA’s Space Launch System. Photo Credit: Orbital ATK</span></p></div> <p>The shuttles employed two four-segment solid rocket boosters during each ascent. Built by what is now <em><strong><a href="https://web.archive.org/web/20200725065447/http://www.orbitalatk.com/" target="_blank">Orbital ATK</a></strong></em>. These Ammonium Perchlorate Composite Propellant (<em><strong><a href="https://web.archive.org/web/20200725065447/https://en.wikipedia.org/wiki/Ammonium_perchlorate_composite_propellant" target="_blank">APCP</a></strong></em>) assistants helped loft a diverse array of payloads and astronauts to orbital elevations, along with the crews of some 135 shuttle missions, for three decades, They are now being repurposed, redesigned, and empowered to send these crews much, much farther.</p> <p>Jessica Widrick is a joints and seals metals design engineer with Orbital ATK; she is one of a new breed of aerospace engineers who has been tasked with preparing NASA’s new super-heavy loft <em><strong><a href="https://web.archive.org/web/20200725065447/https://www.nasa.gov/exploration/systems/sls/" target="_blank">Space Launch System</a></strong></em> booster for flight.</p> <p>Widrick works out of Orbital ATK’s Promontory, Utah, facility. As is the case with most engineers of her caliber, she is a specialist. Her particular focus includes the five-segment solid rocket motor (<em><strong><a href="https://web.archive.org/web/20200725065447/http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/20120014501.pdf" target="_blank">RSRMV</a></strong></em>), the Booster Separation Motors (BSMs), and SLS’ Launch Abort System (LAS).</p> <p>However, that is not precise enough. Widrick’s occupation serves to ensure the safety and performance of some of the key components of these legacy systems. Her work includes all of the SRBs components, the gaskets, O-rings, thermal barrier systems, and other key elements. There have been numerous modifications made to the boosters since the close of the shuttle era in 2011.</p> <p>“The main difference between RSRM and SLS is the insulation change to an asbestos-free insulation so the material the insulation J-leg is composed of changed as well. Of course, biggest field joint/joints and seals change is still the low-temperature capable O-rings and the ability to actually use their low-temperature capability (due to the elimination of heaters),” Widrick told <em>SpaceFlight Insider</em>.</p> <p>In some cases, the changes that were made to produce these new boosters are as deceptively simple as new materials used in the place of those that were used prior to the planned first flight of SLS, slated to take place in 2018. As Widrick noted, the J-joint or J-leg configuration was one of the things changed on the boosters’ design.</p> <div id="attachment_49598" style="width: 410px" class="wp-caption alignleft"><a href="https://web.archive.org/web/20200725065447/http://www.spaceflightinsider.com/wp-content/uploads/2016/01/11223538_10153758703115762_2771389184048260855_n-1.jpg" target="_blank"><img aria-describedby="caption-attachment-49598" class="wp-image-49598" src="https://web.archive.org/web/20200725065447im_/http://www.spaceflightinsider.com/wp-content/uploads/2016/01/11223538_10153758703115762_2771389184048260855_n-1-655x434.jpg" alt="Space Launch System SLS Orbital ATK five segment solid rocket booster NASA photo posted on SpaceFlight Insider" width="400" height="265" srcset="https://web.archive.org/web/20200725065447im_/https://www.spaceflightinsider.com/wp-content/uploads/2016/01/11223538_10153758703115762_2771389184048260855_n-1-655x434.jpg 655w, https://web.archive.org/web/20200725065447im_/https://www.spaceflightinsider.com/wp-content/uploads/2016/01/11223538_10153758703115762_2771389184048260855_n-1-300x199.jpg 300w, https://web.archive.org/web/20200725065447im_/https://www.spaceflightinsider.com/wp-content/uploads/2016/01/11223538_10153758703115762_2771389184048260855_n-1.jpg 685w" sizes="(max-width: 400px) 100vw, 400px"/></a><p id="caption-attachment-49598" class="wp-caption-text">NASA hopes to conduct the first test flight of SLS in the final quarter of 2018. Image Credit: NASA</p></div> <p>“By J-leg configuration, I’m referring to the insulation feature which blocks hot motor gases from directly entering the field joint region. The J-leg (sometimes referred to as a J-Joint) functions when hot motor gas enters a pressurization slot and pushes the J-leg against the mating insulation preventing those hot motor gases from entering the field joint,” Widrick said. “This J-leg feature was one of many added after <em>Challenger</em> to the field joint design to help protect the primary and secondary seals from hot motor gases.”</p> <p>The J-Joint is just one element of a good number of components that have been changed and/or added to the new boosters. The initial design first took to the skies in 1981 with the flight of STS-1; it was subsequently modified throughout the course of the Space Shuttle Program.</p> <p>Each of the boosters weigh <em><strong><a href="https://web.archive.org/web/20200725065447/https://www.orbitalatk.com/flight-systems/propulsion-systems/SLS-solid-rocket-boosters/docs/FS022_15_OA_SLS_Booster.pdf" target="_blank">1.6 million lbs</a></strong></em> – of which 1.5 million lbs is propellant. When activated, this burns at the rate of about 5.5 tons every second (692,500 lbs of propellant every minute). The allows the boosters to deliver some 3,600,000 pounds of maximum thrust.</p> <p>“For the SLS program, changes to the nozzle required new hardware and new nozzle internal joints to be designed which is part of my job as a joints/seal design engineer. For the new nozzle joint designs, the thermal barrier systems were updated to include design features such as carbon fiber rope and barrier O-rings which help protect the primary and secondary seals from hot motor gases. Carbon fiber rope was used in a couple [of] nozzle internal joints during RSRM, but the changes to the nozzle in the SLS program allowed for improvements to all the nozzle joints,” Widrick said.</p> <p>Widrick, like many of her compatriots, cut her teeth during the shuttle era; she has been working on the joints and seals that were used on the shuttle – and those that are planned for use on SLS – for a little more than 9 years.</p> <p>Motivated and fascinated by space flight, Widrick traveled down to attend the launch of Space Shuttle <em>Atlantis</em> in May of 2010 on mission STS-132.</p> <p><span class="embed-youtube" style="text-align:center; display: block;"><iframe class="youtube-player" width="640" height="360" src="https://web.archive.org/web/20200725065447if_/https://www.youtube.com/embed/TG_URKgQKMI?version=3&rel=1&fs=1&autohide=2&showsearch=0&showinfo=1&iv_load_policy=1&wmode=transparent" allowfullscreen="true" style="border:0;"></iframe></span></p> <p style="text-align: center;"><em>Video courtesy of SpaceFlight Insider with NASA elements</em></p> <p> </p> <div class="shareaholic-canvas" data-app="share_buttons" data-title="Four to five: Engineer details changes made to SLS booster" data-link="https://www.spaceflightinsider.com/missions/human-spaceflight/four-five-engineer-details-shuttles-booster-will-used-sls/" data-summary="KENNEDY SPACE CENTER, Fla. — It has been more than forty years since humanity broke free of the bonds of Earth's gravity for points beyond. NASA is working to use existing "legacy" systems – such as the Space Shuttle Program. SFI spoke with one engineer who is working to make this happen." data-app-id="28397423" data-app-id-name="post_below_content"></div> <p class="tags"> Tagged: <a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/tag/lead-stories/" rel="tag">Lead Stories</a> <a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/tag/orbital-atk/" rel="tag">Orbital ATK</a> <a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/tag/promontory-utah/" rel="tag">Promontory Utah</a> <a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/tag/space-launch-system/" rel="tag">Space Launch System</a> </p> <div class="news-post-about"><img alt="" src="https://web.archive.org/web/20200725065447im_/https://secure.gravatar.com/avatar/314f743a52f7df0d72cda1f3a790412f?s=96&d=mm&r=g" srcset="https://web.archive.org/web/20200725065447im_/https://secure.gravatar.com/avatar/314f743a52f7df0d72cda1f3a790412f?s=192&d=mm&r=g 2x" class="avatar avatar-96 photo" height="96" width="96"/> <h3><a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/author/jason-rhian/" title="Posts by Jason Rhian" rel="author">Jason Rhian</a></h3> <p>Jason Rhian spent several years honing his skills with internships at NASA, the National Space Society and other organizations. He has provided content for outlets such as: Aviation Week & Space Technology, Space.com, The Mars Society and Universe Today.</p> </div> </div><div id="jp-relatedposts" class="jp-relatedposts"> <h3 class="jp-relatedposts-headline">Related Reading</h3> </div> <div id="comments" class="comments-area"> <div class="comments-header"> <h3>Reader Comments </h3> </div> <div class="comment-list"> <div class="comment even thread-even depth-1" id="comment-686935"> <div class="comment-info"> <div class="comment-author"> Clio Marsden </div> <div class="comment-meta"> <a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/missions/human-spaceflight/four-five-engineer-details-shuttles-booster-will-used-sls/#comment-686935"> January 10, 2016 4:54 pm</a> </a> </div> </div> <p>“Each of the boosters weigh 1.6 billion lbs – of which 1.5 billion is propellant.”</p> <p>Not on Earth they don’t. I think the units are off here. Good article none the less.</p> <div class="reply"> <a rel="nofollow" class="comment-reply-link" href="#comment-686935" data-commentid="686935" data-postid="48102" data-belowelement="comment-686935" data-respondelement="respond" aria-label="Reply to Clio Marsden">Reply</a> </div> </div> <div class="comment odd alt thread-odd thread-alt depth-1 parent" id="comment-687042"> <div class="comment-info"> <div class="comment-author"> Clive Bashford </div> <div class="comment-meta"> <a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/missions/human-spaceflight/four-five-engineer-details-shuttles-booster-will-used-sls/#comment-687042"> January 11, 2016 2:57 am</a> </a> </div> </div> <p>If one of these boosters failed to fire up, the other one would become a complete nightmare.</p> <div class="reply"> <a rel="nofollow" class="comment-reply-link" href="#comment-687042" data-commentid="687042" data-postid="48102" data-belowelement="comment-687042" data-respondelement="respond" aria-label="Reply to Clive Bashford">Reply</a> </div> <div class="comment even depth-2" id="comment-687809"> <div class="comment-info"> <div class="comment-author"> Brian Posner </div> <div class="comment-meta"> <a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/missions/human-spaceflight/four-five-engineer-details-shuttles-booster-will-used-sls/#comment-687809"> January 13, 2016 3:15 pm</a> </a> </div> </div> <p>That’s why there’s a flight termination system on every solid rocket motor and a range safety officer tasked with destruction of the spacecraft in the event of the vehicle deviating from the proscribed safe path.</p> <div class="reply"> <a rel="nofollow" class="comment-reply-link" href="#comment-687809" data-commentid="687809" data-postid="48102" data-belowelement="comment-687809" data-respondelement="respond" aria-label="Reply to Brian Posner">Reply</a> </div> </div> </div> <div class="comment odd alt thread-even depth-1" id="comment-734147"> <div class="comment-info"> <div class="comment-author"> <a href="https://web.archive.org/web/20200725065447/http://www.rugsandbeyond.com/traditional.html" rel="external nofollow ugc" class="url">Rugsandbeyond</a> </div> <div class="comment-meta"> <a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/missions/human-spaceflight/four-five-engineer-details-shuttles-booster-will-used-sls/#comment-734147"> January 20, 2017 4:32 am</a> </a> </div> </div> <p>Oh my god these are huge. If anyone of these will fire then one can assume what will happen.</p> <div class="reply"> <a rel="nofollow" class="comment-reply-link" href="#comment-734147" data-commentid="734147" data-postid="48102" data-belowelement="comment-734147" data-respondelement="respond" aria-label="Reply to Rugsandbeyond">Reply</a> </div> </div> <div class="comment even thread-odd thread-alt depth-1" id="comment-755565"> <div class="comment-info"> <div class="comment-author"> <a href="https://web.archive.org/web/20200725065447/http://gunsafely.com/" rel="external nofollow ugc" class="url">gunsafely</a> </div> <div class="comment-meta"> <a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/missions/human-spaceflight/four-five-engineer-details-shuttles-booster-will-used-sls/#comment-755565"> December 2, 2017 5:41 am</a> </a> </div> </div> <p>Goodness my god these are gigantic. On the off chance that anybody of these will fire then one can accept what will happen</p> <div class="reply"> <a rel="nofollow" class="comment-reply-link" href="#comment-755565" data-commentid="755565" data-postid="48102" data-belowelement="comment-755565" data-respondelement="respond" aria-label="Reply to gunsafely">Reply</a> </div> </div> </div> <div id="respond" class="comment-respond"> <p class="comment-note"><a href="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/commenting-rules">⚠ Commenting Rules</a></p><h3>Post Comment</h3> <small><a rel="nofollow" id="cancel-comment-reply-link" href="/web/20200725065447/https://www.spaceflightinsider.com/missions/human-spaceflight/four-five-engineer-details-shuttles-booster-will-used-sls/#respond" style="display:none;">Cancel reply</a></small></h3><form action="https://web.archive.org/web/20200725065447/https://www.spaceflightinsider.com/wp-comments-post.php" method="post" id="commentform" class="comment-form"><p class="comment-notes"><span id="email-notes">Your email address will not be published.</span> Required fields are marked <span class="required">*</span></p><p class="comment-form-comment"><textarea autocomplete="nope" id="d6fdb4c9bf" name="d6fdb4c9bf" rows="8" aria-required="true"></textarea><textarea id="comment" aria-hidden="true" name="comment" autocomplete="nope" style="padding:0;clip:rect(1px, 1px, 1px, 1px);position:absolute !important;white-space:nowrap;height:1px;width:1px;overflow:hidden;" tabindex="-1"></textarea><script type="text/javascript">document.getElementById("comment").setAttribute( "id", "ad758d204b1a42fa73f843b1e2881eef" );document.getElementById("d6fdb4c9bf").setAttribute( "id", "comment" );</script></p><p class="comment-form-author"><label for="author">Name <span class="required">*</span></label> <input id="author" name="author" type="text" value="" size="30" maxlength="245" required="required"/></p> <p class="comment-form-email"><label for="email">Email <span class="required">*</span></label> <input id="email" name="email" type="text" value="" size="30" maxlength="100" aria-describedby="email-notes" required="required"/></p> <p class="comment-form-url"><label for="url">Website</label> <input id="url" name="url" type="text" value="" size="30" maxlength="200"/></p> <p class="comment-subscription-form"><input type="checkbox" name="subscribe_comments" id="subscribe_comments" value="subscribe" style="width: auto; 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