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January 26, 2012

Stennis testing next generation space flight engines

STENNIS SPACE CENTER — Testing and development of the next engine that will take humans beyond low Earth orbit is underway.

The engine is touted as next generation but is actually based on an engine from the Apollo era, the J2. Through modifications, the engine will see new life, provide more thrust and be more efficient, said Tom Byrd, J2X Engine lead with Marshall Space Flight. Test stands currently testing the engine also are from the Apollo era, the A-1 and A-2 test stands.

The engines will be used in the new manned heavy lift vehicle, currently called the Space Launch System.

NASA still has plans for the shuttle’s main engines, even though the space shuttle program was retired. Those engines will be used as boosters to bring the SLS from sea level to low Earth orbit, said James Wahl, with Pratt Whitney Rocketdyne Business Development and Strategic Planning.

Once in low Earth orbit, the J2X will fire to bring the SLS out of Earth’s orbit and into deep space, Byrd said. Since the engine will be used primarily at very high altitudes, Stennis will need a way to simulate those conditions for testing.

That is where the A-2 test stand will come in, at first. Skip Roberts, A-2 Test Director, said the stand is capable of simulating altitudes of 50,000 feet using a large diffuser attached to the stand.

Currently, a variation of the J2X power pack is being tested under sea level conditions at the A-1 test stand. A-1 Test Director Jeff Henderson said a power pack is essentially a rocket engine without the parts that provide thrust. Testing a power pack as opposed to an entire engine allows for more variance during testing, Byrd said.

The role of the A-3 test stand, which is currently under construction, will be to test the engine in a simulated environment higher than 50,000 feet. Tom Rich, A-3 Construction Manager, said once completed, the stand will simulate conditions of 100,000 feet, which is the edge of space. While the stand is expected to be completed in about a year, activation of the stand will begin in August of 2013. Activation of the stand will entail testing only the altitude simulation properties of the stand. Engine testing will not occur until the specifications for the engine NASA wishes to test are finalized, Rich said.

Byrd said teams are looking at two configurations of the J2X: One with a stub nozzle and another with a full nozzle. No matter which engine is decided upon, Byrd foresees the A-3 test stand being used for a long time.

“This is going to be used for decades. I’m sure we’ll see it used for all sorts of things,” Byrd said.

Unlike the A-2’s diffuser, the A-3 will use an enclosure and other specialized equipment to simulate the high altitudes, Rich said.

Workers at Pratt Whitney Rocketdyne are working with the nuts and bolts of the J2X, taking parts off and replacing them with others to achieve the performance levels needed to bring humans into deep space, said Wahl.

The old shuttle engines to be used in the booster stage of the SLS also are being stored at Pratt Whitney. He said 15 of the old shuttle engines, which had been used during the shuttle program, will be relocated from Kennedy Space Center to Pratt Whitney at Stennis by April. Those engines also will be tested once more at Stennis, after they undergo modifications to meet the needs of their new job, Wahl said.

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