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The Marshall Star for August 7, 2024


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The Marshall Star for August 7, 2024

A man and women look at a piece of hardware

NASA Additive Manufacturing Project Shapes Future for Agency, Industry Rocket Makers

The widespread commercial adoption of additive manufacturing technologies, commonly known as 3D printing, is no surprise to design engineers at NASA’s Marshall Space Flight Center whose research created stronger, lighter weight materials and new manufacturing processes to make rocket parts.

NASA’s RAMPT (Rapid Analysis and Manufacturing Propulsion Technology) project is on the cutting edge of additive manufacturing – helping the agency and industry produce new alloys and additively manufactured parts, commonly referred to as 3D printing, according to Paul Gradl, the project’s co-principal investigator at Marshall.

“Across NASA’s storied legacy of vehicle and hardware design, testing, and integration, our underlying strength is in our application of extremely durable and severe environment materials and innovative manufacturing for component design,” said Gradl. “We strive to fully understand the microstructure and properties of every material and how they will ultimately be used in components before we make them available to industry for flight applications.”

The same principle applies to additive manufacturing, the meticulous process of building components and hardware one layer of material at a time.

An info graphic shows the different sections of a testing article
The graphic captures additive manufacturing technology milestones led by the RAMPT project. Using 3D-printed, liquid oxygen/hydrogen thrust chamber hardware at chamber pressures of up to 1,400 pounds per square inch, Marshall engineers have completed 12 hot-fire tests totaling a combined 330 seconds. The project also has delivered composite materials demonstrating a 40% weight savings over conventional bimetallic combustion chambers. NASA and its industry partners are working to make this cutting-edge technology accessible for a host of future NASA and commercial space missions.
NASA/Pablo Garcia

“The RAMPT project’s goal is to support commercial, technical readiness, enabling our industry partners to meet the challenges inherent in building new generations of safer, more cost-effective deep space exploration propulsion systems,” said John Fikes, RAMPT project manager.

Since its inception, RAMPT has conducted 500 test-firings of 3D-printed injectors, nozzles, and chamber hardware totaling more than 16,000 seconds, using newly developed extreme-environment alloys, large-scale additive manufacturing processes, and advanced composite technology. The project has also started developing a full-scale version for the workhorse RS-25 engine – which experts say could reduce its costs by up to 70% and cut manufacturing time in half.

As printed structures are getting bigger and more complex, a major area of interest is the additive manufacturing print scale. A decade ago, most 3D-printed parts were no bigger than a shoebox. Today, additive manufacturing researchers are helping the industry produce lighter, more robust, intricately designed rocket engine components 10-feet tall and eight-feet in diameter.

“NASA, through public-private partnerships, is making these breakthroughs accessible to the commercial space industry to help them rapidly advance new flight technologies of their own,” Gradl said. “We’re solving technical challenges, creating new supply chains for parts and materials, and increasing the industry’s capacity to rapidly deliver reliable hardware that draws a busy commercial space infrastructure ever closer.”

The RAMPT project does not just develop the end technology but the means to fully understand that technology, whatever the application. That means advancing cutting-edge simulation tools that can identify the viability of new alloys and composites at the microstructural level – assessing how they handle the fiery rigors of liftoff, the punishing cold of space, and the dynamic stresses associated with liftoffs, landings, and the long transits between.

NASA’s strategy to encourage commercial and academic buy-in is to offer public-private partnership opportunities, wherein industry and academia contribute as much as 25% of project development costs, allowing them to reap the benefits.

For example, NASA successfully delivered a refined version of an alloy, known as GRCop42, created at NASA’s Glenn Research Center nearly 40 years ago which helped commercial launch provider, Relativity Space, launch the first fully 3D-printed rocket in March 2023.

“Our primary goal with these higher-performance alloys is to prove them in a rocket engine test-fire environment and then hand them off to enable commercial providers to build hardware, fly launch vehicles, and foster a thriving space infrastructure with real scientific, social, and economic rewards,” Gradl said.

A key benefit of additive manufacturing hardware development is radically reducing the “design-fail-fix” cycle – when engineers develop new hardware, ground-test it to failure to determine the hardware’s design limits under all possible conditions and then tweak accordingly. That capability is increasingly important with the creation of new alloys and designs, new processing techniques, and the introduction of composite overwraps and other innovations.

A hot fire test shows an orange flame coming out of a 3D printed chamber.
Shown during a hot-fire test at Marshall, this 2,000-pound-force coupled thrust chamber assembly features a NASA HR-1 alloy nozzle. Manufacturing the hardware requires the directed energy deposition process with composite-overwrap for structural support, reducing weight by 40%. Industry, academic, and government partners are working with RAMPT engineers at Marshall and other NASA field centers to advance this revolutionary technology.
NASA

The RAMPT project did just that, successfully advancing new additive manufacturing alloys and processes, integrating them with carbon-fiber composites to reduce weight by up to 40%, developing and validating new simulation tools – and making all this data available to industry through public-private partnerships.

“We’re able to deliver prototypes in weeks instead of years, conduct dozens of scaled ground tests in a period that would feasibly permit just one or two such tests of conventionally manufactured hardware, and most importantly, deliver technology solutions that are safer, lighter, and less costly than traditional components,” Gradl said.

Fikes added, “Ten years from now, we may be building rocket engines – or rockets themselves – out of entirely new materials, employing all-new processing and fabrication techniques. NASA is central to all of that.”

The RAMPT project continues to progress and receive recognition from NASA and industry partners. On July 31, the RAMPT team was awarded NASA’s 2024 Invention of The Year award for its excellence and contributions to NASA and the commercial industry’s deep space exploration goals.

Marshall leads RAMPT, with key support among engineers and technologists at NASA’s Glenn Research Center; Ames Research Center; Langley Research Center; and Auburn University in Auburn, Alabama, plus contributions from other academic partners and industry contractors. RAMPT is funded by NASA’s Game Changing Development Program within the agency’s Space Technology Mission Directorate.

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Artemis Mission Manager Mike Sarafin Speaker for Aug. 8 Mission Success Forum

By Wayne Smith

Mike Sarafin, Artemis mission manager and Mission Management Team chair, will be the guest speaker for the Mission Success is in Our Hands Shared Experiences Forum on Aug. 8 at NASA’s Marshall Space Flight Center.

etv-min.jpg?w=1920
The forum will take place in Activities Building 4316 and on Teams.

The 11:30 a.m. event will be in Activities Building 4316 and Marshall team members are encouraged to attend. The forum is available to NASA employees and the public virtually via Teams.

Mission Success is in Our Hands is a safety initiative collaboration between NASA’s Marshall Space Flight Center and Jacobs Engineering. The initiative’s goal to help team members make meaningful connections between their jobs and the safety and success of NASA and Marshall missions.

The theme of the forum is “Artemis I Mission Challenges.” Sarafin will provide a frontline perspective on the role of the Mission Management Team and how it is governed. He will summarize key challenges encountered, suggest best practices for managing large diverse teams, discuss useful risk informed decision-making tools, and highlight lessons learned for consideration in future human lunar exploration missions.

“As we continue to prepare for the next Artemis mission, this forum is a valuable opportunity to learn about challenges NASA faced to ensure mission success for Artemis I,” said Bill Hill, director of the Safety and Mission Assurance Directorate at Marshall. “I encourage Marshall team members to attend the forum in person to gain Mike’s insight on safety and mission success.”

Sarafin is the Artemis mission manager for the Moon to Mars Program Office at NASA Headquarters. In this role, he leads the Mission Management Team for Artemis, providing oversight and responsibility for critical decisions across all flight phases (launch, in-space, and recovery), with support from team members and advisors with technical expertise in various areas. Prior to flight, he acted as a senior technical leader integrating mission requirements, planning, operations, and flight readiness leading to mission execution.

With more than 30 years of human spaceflight experience, Sarafin began his career as a guidance, navigation, and mission controller working on the space shuttle. He became a NASA flight director supporting the space shuttle and the International Space Station. He also was the lead flight director for Orion’s first flight test in 2014.

As part of the forum, Mission Success is in Our Hands will present the Golden Eagle Award to a Marshall team member. The award promotes awareness and appreciation for flight safety, as demonstrated through the connections between employees’ everyday work, the success of NASA and Marshall’s missions, and the safety of NASA astronauts. The award recognizes individuals who have made significant contributions to flight safety and mission assurance above and beyond their normal work requirements. Management or peers can nominate any team member for the award. Honorees are typically recognized at quarterly Shared Experiences forums.

The next Shared Experiences Forum is scheduled for Sept. 5, featuring Dave Dykhoff, former vice president and general manager of the Jacobs Missile Defense Group and the NORAD Operations Group.

Smith, a Media Fusion employee and the Marshall Star editor, supports the Marshall Office of Communications.

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Denise Smithers Named Marshall’s Center Executive Officer

Denise Smithers has been named to the position of center executive officer as part of a six-month detail supporting the Office of the Center Director at NASA’s Marshall Space Flight Center, effective Aug. 9. As center executive officer, Smithers will lead the overall office management and operations within the director’s office, integrate and coordinate center-wide actions, and serve as Marshall’s chief of staff.

denisesmithers.jpg?w=2048
Denise Smithers has been named to the position of center executive officer as part of a six-month detail supporting the Office of the Center Director at NASA’s Marshall Space Flight Center.
NASA

Smithers has been with Marshall for more than 30 years, holding various budget, strategic, and leadership positions. Since July 2020, Smithers has served as a supervisory budget analyst for the Mission Support Office, overseeing a team of analysts in managing budgets for institutional support offices. While working in the Budget, Integration, and Analysis Team in the Office of the Chief Financial Officer (OCFO), she developed strategic guidance, managed processes, and provided in-depth analyses for the annual Planning, Programming, Budget, and Execution process. She was also responsible for reporting on financial performances, assessing trends, addressing cost-cutting issues, identifying risks, and providing strategic budgetary decisions.

Before joining OCFO, Smither’s previous roles included deputy director of the Office of Diversity and Equal Opportunity (ODEO) from 2019-2020, where she promoted education, awareness, and communication of diversity initiatives to Marshall’s workforce; lead budget analyst supporting the Chief Information Office from 2014-2019; external relations specialist from 2013-2014; technical assistant supporting the Office of the Center Director from 2011-2013; budget analyst from 2000-2013; and contract specialist from 1996-2000.

Smithers started her tenure at Marshall at 18 as a summer intern. In addition to her job duties, she is active in many community civic organizations and Employee Resource Groups (ERGs) at Marshall. She leads the OCFO Enterprise Diversity Equity Inclusion and Accessibility (DEIA) Culture, Branding, and Vision Team, and represents management on their focus team. She was appointed to the Marshall Culture Advisory Committee where she develops, implements, and accesses DEIA strategies and initiatives in collaboration with ODEO. Smithers also leads the Women’s ERG at Marshall and serves as the Blueprint to Reinforce Inclusivity and Diversity to Gain Equity (BRIDGE) Champion representative for OCFO.

A native of Athens, Alabama, Smithers earned a Master of Business Administration from Alabama A&M University and a Bachelor of Science degree from the University of Alabama in Huntsville. She was awarded a Silver Snoopy in 2011, a Director’s Commendation in 2019, and the Agency DEIA Medal in 2023.

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Shooting Stars: Annual Perseid Meteor Shower to Peak Aug. 11-12

By Wayne Smith

They may not attract as much attention as last month’s daylight fireball over New York City, but stargazers can still anticipate seeing some shooting stars with the upcoming Perseid meteor shower. Caused by Earth passing through trails of debris left behind by Comet Swift-Tuttle, the shower has become famous over the centuries because of its consistent display of celestial fireworks.

A bright meteor leaves a trail of light amongst a sky full of stars. Silhouettes of trees frame the bottom of the image.
In this 30 second exposure, a meteor streaks across the sky during the annual Perseid meteor shower, Wednesday, Aug. 11, 2021, in Spruce Knob, West Virginia.
NASA/Bill Ingalls

“The Perseids is the best annual meteor shower for the casual stargazer,” said Bill Cooke, who leads NASA’s Meteoroid Environment Office at the agency’s Marshall Space Flight Center. “Not only is the shower rich in bright meteors and fireballs – No. 1 in fact – it also peaks in mid-August when the weather is still warm and comfortable. This year, the Perseid maximum will occur on the night of Aug. 11 and pre-dawn hours of Aug. 12. You’ll start seeing meteors from the shower around 11 p.m. local time and the rates will increase until dawn. If you miss the night of the 11th, you will also be able to see quite a few on the night of the 12th between those times.”

The best way to see the Perseids is to find the darkest possible sky and visit between midnight and dawn on the morning of Aug. 12. Allow about 45 minutes for your eyes to adjust to the dark. Lie on your back and look straight up. Avoid looking at cell phones or tablets because their bright screens ruin night vision and take your eyes off the sky.

Perseid meteors travel at the blistering speed of 132,000 mph – or 500 times faster than the fastest car in the world. At that speed, even a smidgen of dust makes a vivid streak of light when it collides with Earth’s atmosphere. Peak temperatures can exceed 3,000 degrees Fahrenheit as they speed across the sky. The Perseids pose no danger to people on the ground as practically all burn up 60 miles above our planet.

The first Perseid captured by NASA’s All Sky Meteor Camera Network was recorded at 9:48 p.m. EDT on July 23. The meteor – about as bright as the planet Jupiter, so not quite bright enough to be considered a fireball – was caused by a piece of Comet Swift-Tuttle about 5 millimeters in diameter entering the atmosphere over the Atlantic and burning up 66 miles above St. Cloud, Florida, just south of Orlando.

A bright streak is shown going across the sky.
NASA’s All Sky Meteor Camera Network captured its first Perseid at 8:48 p.m. CDT on July 23.
NASA

Rare Fireball in New York, New York Not Perseids

It wasn’t part of the Perseids, but a rare daylight fireball streaked across the sky over New York City at 11:15 a.m. EDT on  July 16. The event gained national attention and was reported in media outlets across the U.S.

The fireball, defined as a meteor brighter than the planet Venus, is estimated to have soared over New York City before traversing a short path southwest and disintegrating about 31 miles above Mountainside, New Jersey. Cooke said the meteor was likely about 1 foot in diameter, which would have made the rock bright enough to see during the day. Seeing a meteor of this size is rarer than catching sight of the smaller particles a few millimeters in size typically seen in the night sky.

“To see one in the daytime over a populated area like New York is fairly rare,” Cooke said during an interview with ABC 7 in New York.

The Meteoroid Environments Office studies meteoroids in space so that NASA can protect our nation’s satellites, spacecraft and even astronauts aboard the International Space Station from these bits of tiny space debris.

For more skywatching highlights in April, check out Jet Propulsion Lab’s What’s Up series.

Smith, a Media Fusion employee and the Marshall Star editor, supports the Marshall Office of Communications.

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NASA Invites Public to Attend Deep Space Food Challenge Finale

NASA invites the public to explore the nexus of space and food innovation at the agency’s Deep Space Food Challenge symposium and winners’ announcement at the Nationwide and Ohio Farm Bureau 4-H Center in Columbus, Ohio, on Aug. 16. 

In 2019, NASA and the CSA (Canadian Space Agency) started the Deep Space Food Challenge, a multi-year international effort to develop sustainable food systems for long-duration habitation in space including the Moon and Mars. Since Phase 1 of the challenge opened in 2021, more than 300 teams from 32 countries have developed innovative food system designs. On Aug. 16, NASA will announce the final Phase 3 winners and recognize the shared global effort.

An artists’ rendering of the Moon and Mars, both halfway lit, above the Earth’s horizon against open space, sprinkled with small stars.
NASA’s Deep Space Food Challenge directly supports the agency’s Moon to Mars initiatives.
Credit: NASA

NASA will award up to $1.5 million during the awards ceremony, totaling the prize purse for this three-year competition at $3 million. International teams also will be recognized for their achievements.

“Advanced food systems also benefit life on Earth,” said Kim Krome-Sieja, acting program manager of NASA Centennial Challenges at NASA’s Marshall Space Flight Center. “Solutions from this challenge could enable new avenues for food production around the world, especially in extreme environments, resource-scarce regions, and in locations where disasters disrupt critical infrastructure.”

The Methuselah Foundation, NASA’s partner in the Deep Space Food Challenge, is hosting the event in coordination with the Ohio State University College of Food, Agricultural, and Environmental Sciences and NASA Centennial Challenges.

“Our Phase 2 winners’ event in Brooklyn, New York, was an incredible display of innovation, partnership, and collaboration across NASA, industry, and academia,” said Angela Herblet, challenge manager of the Deep Space Food Challenge and program analyst of NASA Centennial Challenges at Marshall. “I’m looking forward to celebrating these brilliant Phase 3 finalists and underscoring the giant leaps they’ve made toward creating sustainable, regenerative food production systems.” 

The event will feature a meet and greet with the Phase 3 finalists, symposium panels, and live demonstrations of the finalists’ food production technologies. Attendees also will have the opportunity to meet the crew of Ohio State students called “Simunauts,” who managed operations of the technologies during the eight-week demonstration and testing period.

“The Prizes, Challenges, and Crowdsourcing team is excited to welcome media, stakeholders, and the public to our event in Columbus,” said Amy Kaminski, program executive for NASA’s Prizes, Challenges, and Crowdsourcing at NASA Headquarters. “These finalists have worked diligently for three years to develop their diverse, innovative food systems, and I’m excited to see how their technologies may impact NASA’s future deep space missions.”

The awards ceremony also will livestream on Marshall Space Flight Center’s YouTube channel and NASA Prize’s Facebook page.

As a NASA Centennial Challenge, the Deep Space Food Challenge is a coordinated effort between NASA and CSA for the benefit of all. Subject matter experts at NASA’s Johnson Space Center and NASA’s Kennedy Space Center support the competition. NASA’s Centennial Challenges are part of the Prizes, Challenges, and Crowdsourcing program within NASA’s Space Technology Mission Directorate and managed at Marshall. The Methuselah Foundation, in partnership with NASA, oversees the competitors.

For more information about the symposium, see the symposium website. Learn more about the Deep Space Food Challenge.

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Artemis Emergency Egress System Emphasizes Crew Safety 

Since NASA began sending astronauts to space, the agency has relied on emergency systems for personnel to safely leave the launch pad and escape the hazard in the unlikely event of an emergency during the launch countdown. 

Image shows egress baskets that will transport astronauts and personnel from the crew access arm to the launch pad in case of an emergency
Teams with NASA’s Exploration Ground Systems Program, in preparation for the agency’s Artemis II crewed mission to the Moon, conduct testing of four emergency egress baskets on the mobile launcher at Launch Complex 39B at the agency’s Kennedy Space Center in Florida in July 2024. The baskets are used in the case of a pad abort emergency to allow astronauts and other pad personnel to escape quickly from the mobile launcher to the base of the pad to be driven to safety by emergency transport vehicles.
NASA/Amanda Arrieta

During the Mercury and Gemini programs, NASA used launch escape systems on spacecraft for the crew to safely evacuate if needed. Though these systems are still in use for spacecraft today, the emergency routes on the ground were updated starting with the Apollo missions to account for not only the crew, but all remaining personnel at the launch pad. 

During Apollo, personnel relied on a ground-based emergency egress system – or emergency exit route – to allow for a quick and safe departure. Though the system has varied over time and different launch pads use different escape systems, the overall goal has stayed the same – quickly leave the launch pad and head to safety.  

Beginning with Artemis II, the Exploration Ground Systems (EGS) Program at Kennedy Space Center, will use a track cable which connects the mobile launcher to the perimeter area of the launch pad where four baskets, similar to gondolas at ski lifts, can ride down. Once down at the ground level, armored emergency response vehicles are stationed to take personnel safely away from the launch pad to one of the triage site locations at Kennedy. 

“We have four baskets that sit on the side of the mobile launcher tower at the same level as the crew access arm, the location where the crew enters the spacecraft,” said Amanda Arrieta, mobile launcher 1 senior element engineer for NASA’s EGS Program. “The intention is to provide another means of egress for the crew and the closeout crew in the event of an emergency. Each of these baskets will go down a wire. It’s a wire rope system that connects to the pad terminus, an area near the pad perimeter where the baskets will land after leaving the mobile launcher tower.” 

The Artemis system works like this: personnel will exit the Orion spacecraft or the white room (depending where teams are at the time of the emergency) inside the crew access arm of the mobile launcher. Located on the 274-foot-level, teams are approximately 375 feet above the ground. From there, they will head down the 1,335-foot-long cables inside the emergency egress baskets to the launch pad perimeter, or the pad terminus area. Each basket, which is similar in size to a small SUV, is designed to carry up to five people or a maximum weight of 1,500 pounds.

artemis-emergency-egress-system-infograp
Infographic shows the route astronauts and personnel would take during an emergency abort situation. Credit: NASA

Once teams have left the terminus area and arrive at the triage site location, emergency response crews are there to evaluate and take care of any personnel. 

“When we send our crews to the pad during launch, their safety is always at the forefront of our minds. While it is very unlikely that we will need the emergency egress and pad abort systems, they are built and tested to ensure that if we do need them then they are ready to go,” said Charlie Blackwell-Thompson, Artemis launch director. “Our upcoming integrated ground systems training is about demonstrating the capability of the entire emergency egress response from the time an emergency condition is declared until we have the crews, both flight and ground, safely accounted for outside the hazardous area.”  

For the agency’s Commercial Crew Program, SpaceX uses a slidewire cable with baskets that ride down the cable at the Launch Complex 39A pad. At Space Launch Complex 40, meanwhile, the team uses a deployable chute for its emergency egress system. Boeing and United Launch Alliance also use a slidewire, but instead of baskets, the team deploys seats that ride down the slide wires, similar to riding down a zip line, at Space Launch Complex 41 at Cape Canaveral Space Force Station.  

Artemis II will be NASA’s first mission with crew aboard the SLS (Space Launch System) rocket and Orion spacecraft and will also introduce several new ground systems for the first time – including the emergency egress system. Though no NASA mission to date has needed to use its ground-based emergency egress system during launch countdown, those safety measures are still in place and maintained as a top priority for the agency. 

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NASA Sends More Science to Space, More Strides for Future Exploration

New experiments aboard NASA’s Northrop Grumman 21st cargo resupply mission aim to pioneer scientific discoveries in microgravity on the International Space Station.

Northrop Grumman’s Cygnus spacecraft, filled with nearly 8,500 pounds of supplies, launched Aug. 4 atop a SpaceX Falcon 9 rocket from Space Launch Complex 40 at Cape Canaveral Space Force Station. Biological and physical investigations aboard the spacecraft included experiments studying the impacts of microgravity on plants (grass), how packed bed reactors could improve water purification both in space and on Earth, and observations on new rounds of samples that will allow scientists to learn more about the characteristics of different materials as they change phases on the tiniest scales.

A split screen containing two square boxes, filtered by a cool magenta light. Each box is divided into nine smaller boxes containing plants at various stages of growth.
Seedlings germinating for the APEX-09 C4 Space investigation.
NASA

Grass Growth & Bio-Regenerative Support

The cultivation of plants is crucial for developing bio-regenerative life support systems in space. However, growing them in microgravity affects photosynthesis, the process by which plants generate oxygen and convert carbon dioxide into food for astronauts. The C4 Photosynthesis in Space Advanced Plant Experiment-09 investigation will study how two grasses (Brachypodium distachyon and Setaria viridis), with different approaches to photosynthesis, respond to microgravity and high carbon dioxide levels during the spaceflight. The insights gained from this research will pave the way for more effective integration of plants on Earth and in future space habitats. This experiment was originally scheduled to be aboard NASA’s SpaceX 30th cargo resupply mission but was moved to the NG-21 launch.

Water Purification & Gravity

The Packed Bed Reactor Experiment – Water Recovery Series aboard NG-21 will be operated on the space station and will study the hydrodynamics (pressure drop, flow regimes, and flow instability) of two-phase flow (nitrogen gas-water mixture) in microgravity in various types of filters and openings. These samples are important for fluid systems used in life support and water purification and recovery processes. Outcomes of this research will be used to develop design tools and correlations for pressure drop prediction across the various prototypes used in lunar and Martian missions and beyond. 

A complex scientific instrument sits atop a table lined with blue paper. The instrument is comprised of a metal framework with a grayish tube running its length. The torso of a scientist is in the background, his blue-gloved hand inspecting the instrument.
PBRE test Module hardware will be modified to accept the eight PBRE-WR Series test section inserts.
NASA

Removing Impurities in Melted Materials

The Electrostatic Levitation Furnace–4 experiment led by JAXA (Japan Aerospace Exploration Agency), one of NASA’s space station international partners, includes 20 new test samples. Its goal is to continue establishing guidelines for measuring different thermophysical properties of various samples at temperatures greater than 2,000 degrees Celsius.

Transforming raw materials from a liquid to solid form requires the use of a container, known as a crucible, which is used to both heat and hold the substance as it cools down and hardens. During this process, a chemical reaction occurs between the substance and the crucible, and impurities are released and absorbed in the plasma. The Electrostatic Levitation Furnace is the hardware that allows scientists to remove this contaminating part of the process by creating space between the liquid and container – levitating the sample while heated.

A Japanese astronaut smiles at the camera as he installs equipment against a wall of wires and hardware.
Expedition 65 Commander Akihiko Hoshide of the Japan Aerospace Exploration Agency (JAXA) changes out a sample holder in the Electrostatic Levitation Furnace (ELF) located inside JAXA’s Kibo laboratory module. The ELF can heat samples above 2000 degrees Celsius, using a semiconductor laser from four different directions, and can also measure the thermophysical properties (density, surface tension, and viscosity) of high temperature materials, which are very difficult to measure on the Earth.
NASA

More Materials Science: Getting to the Core

The Electromagnetic Levitator, an ESA (European Space Agency) levitation facility, which is celebrating a decade aboard the International Space Station, enables scientists to conduct materials research on at least two elements, known as alloys, in a microgravity environment. By studying the core of the physics taking place, researchers can perform experiments to better understand the steps leading up to solidifying and changing phases. This knowledge could contribute to advancements in the manufacturing industry by providing scientists with more information to develop the latest and more reliable materials for activities like 3D printing.

An astronaut wearing a short-sleeved black polo shirt with his back to the camera appears to be working on a piece of metal equipment, The equipment is shaped rectangular-shaped and juts out from a wall of exposed wires and other metal parts.
European Space Agency astronaut Alexander Gerst, Expedition 41 flight engineer, works with Electromagnetic Levitation hardware in the Columbus laboratory of the International Space Station.
NASA

NASA’s Biological and Physical Sciences Division pioneers scientific discovery and enables exploration by using space environments to conduct investigations not possible on Earth. Studying biological and physical phenomenon under extreme conditions allows researchers to advance the fundamental scientific knowledge required to go farther and stay longer in space, while also benefitting life on Earth.

The Huntsville Operations Support Center (HOSC) at NASA’s Marshall Space Flight Center provides engineering and mission operations support for the space station, the Commercial Crew Program, and Artemis missions, as well as science and technology demonstration missions. The Payload Operations Integration Center within HOSC operates, plans, and coordinates the science experiments onboard the space station 365 days a year, 24 hours a day.

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Aug 07, 2024
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      NASA’s Student Launch competition kicks off its 25th year with the release of the 2025 handbook, detailing how teams can submit proposals by Sept. 11 for the event scheduled next spring near NASA’s Marshall Space Flight Center.
      Student Launch is an annual competition challenging middle school, high school, and college students to design, build, test, and launch a high-powered amateur rocket with a scientific or engineering payload. After a team is selected, they must meet documentation milestones and undergo detailed reviews throughout the school year.
      NASA’s Student Launch, a STEM competition, officially kicks off its 25th anniversary with the 2025 handbook.NASA Each year, NASA updates the university payload challenge to reflect current scientific and exploration missions. For the 2025 season, the payload challenge will again take inspiration from the Artemis missions, which seek to land the first woman and first person of color on the Moon.
      As Student Launch celebrates its 25th anniversary, the payload challenge will include “reports” from STEMnauts, non-living objects representing astronauts. The 2024 challenge tasked teams with safely deploying a lander mid-air for a group of four STEMnauts using metrics to support a survivable landing. The lander had to be deployed without a parachute and had a minimum weight limit of five pounds.
      “This year, we’re shifting the focus to communications for the payload challenge,” said John Eckhart, technical coordinator for Student Launch at Marshall. “The STEMnaut ‘crew’ must relay real-time data to the student team’s mission control. This helps connect Student Launch with the Artemis missions when NASA lands astronauts on the Moon.”
      Thousands of students participated in the 2024 Student Launch competition – making up 70 teams representing 24 states and Puerto Rico. Teams launched their rockets to an altitude between 4,000 and 6,000 feet, while attempting to make a successful landing and executing the payload mission. The University of Notre Dame was the overall winner of the 2024 event, which culminated with a launch day open to the public.
      Student Launch began in 2000 when former Marshall Director Art Stephenson started a student rocket competition at the center. It started with just two universities in Huntsville competing – Alabama A&M University and the University of Alabama in Huntsville – but has continued to soar. Since its inception, thousands of students have participated in the agency’s STEM competition, with many going on to a career with NASA.
      “This remarkable journey, spanning a quarter of a century, has been a testament to the dedication, ingenuity, and passion of countless students, educators, and mentors who have contributed to the program’s success,” Eckhart said. “NASA Student Launch has been at the forefront of experiential education, providing students from middle school through university with unparalleled opportunities to engage in real-world engineering and scientific research. The program’s core mission – to inspire and cultivate the next generation of aerospace professionals and space explorers – has not only been met but exceeded in ways we could have only dreamed of.”
      To encourage students to pursue degrees and careers in STEM (science, technology, engineering, and math), Marshall’s Office of STEM Engagement hosts Student Launch, providing them with real-world experiences. Student Launch is one of NASA’s nine Artemis Student Challenges – a variety of activities that expose students to the knowledge and technology required to achieve the goals of Artemis. 
      In addition to the NASA Office of STEM Engagement’s Next Generation STEM project, NASA Space Operations Mission Directorate, Northrup Grumman, National Space Club Huntsville, American Institute of Aeronautics and Astronautics, National Association of Rocketry, Relativity Space and Bastion Technologies provide funding and leadership for the competition. 
      “These bright students rise to a nine-month challenge for Student Launch that tests their skills in engineering, design, and teamwork,” said Kevin McGhaw, director of NASA’s Office of STEM Engagement Southeast Region. “They are the Artemis Generation, the future scientists, engineers, and innovators who will lead us into the future of space exploration.”
      Smith, a Media Fusion employee and the Marshall Star editor, supports the Marshall Office of Communications.
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      NASA Expands Human Exploration Rover Challenge to Middle Schools
      By Wayne Smith
      Following a 2024 competition that garnered international attention, NASA is expanding its Human Exploration Rover Challenge (HERC) to include a remote control division and inviting middle school students to participate.
      The 31st annual competition is scheduled for April 11-12, 2025, at the U.S. Space & Rocket Center, near NASA’s Marshall Space Flight Center. HERC is managed by NASA’s Southeast Regional Office of STEM Engagement at Marshall. The HERC 2025 Handbook has been released, with guidelines for the new remote control (RC) division – ROVR (Remote-Operated Vehicular Research) – and detailing updates for the human-powered division.
      The cover of the HERC 2025 handbook, which is now available online.NASA “Our RC division significantly lowers the barrier to entry for schools who don’t have access to manufacturing facilities, have less funding, or who are motivated to compete but don’t have the technical mentorship required to design and manufacture a safe human-powered rover,” said Chris Joren, HERC technical coordinator. “We are also opening up HERC to middle school students for the first time. The RC division is inherently safer and less physically intensive, so we invite middle school teams and organizations to submit a proposal to be a part of HERC 2025.”
      Another change for 2025 is the removal of task sites on the course for the human-powered rover division, allowing teams to focus on their rover’s design. Recognized as NASA’s leading international student challenge, the 2025 challenge aims to put competitors in the mindset of the Artemis campaign as they pitch an engineering design for a lunar terrain vehicle – they are astronauts piloting a vehicle, exploring the lunar surface while overcoming various obstacles.
      “The HERC team wanted to put together a challenge that allows students to gain 21st century skills, workforce readiness skills, and skills that are transferable,” said Vemitra Alexander, HERC activity lead. “The students have opportunities to learn and apply the engineering design process model, gain public speaking skills, participate in community outreach, and learn the art of collaborating with their peers. I am very excited about HERC’s growth and the impact it has on the students we serve nationally and internationally.”
      Students interested in designing, developing, building, and testing rovers for Moon and Mars exploration are invited to submit their proposals to NASA through Sept. 19.
      More than 1,000 students with 72 teams from around the world participated in the 2024 challenge as HERC celebrated its 30th anniversary as a NASA competition. Participating teams represented 42 colleges and universities and 30 high schools from 24 states, the District of Columbia, Puerto Rico, and 13 other nations from around the world.
      “We saw a massive jump in recognition, not only from within the agency as NASA Chief Technologist A.C. Charania attended the event, but with several of our international teams meeting dignitaries and ambassadors from their home countries to cheer them on,” Joren said. “The most impressive thing will always be the dedication and resilience of the students and their mentors. No matter what gets thrown at these students, they still roll up to the start line singing songs and waving flags.”
      HERC is one of NASA’s eight Artemis Student Challenges reflecting the goals of the Artemis campaign, which seeks to land the first woman and first person of color on the Moon while establishing a long-term presence for science and exploration. NASA uses such challenges to encourage students to pursue degrees and careers in the STEM fields of science, technology, engineering, and mathematics. 
      Since its inception in 1994, more than 15,000 students have participated in HERC – with many former students now working at NASA, or within the aerospace industry.    
      Smith, a Media Fusion employee and the Marshall Star editor, supports the Marshall Office of Communications.
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      New NASA Sonifications Listen to the Universe’s Past
      A quarter of a century ago, NASA released the “first light” images from the agency’s Chandra X-ray Observatory. This introduction to the world of Chandra’s high-resolution X-ray imaging capabilities included an unprecedented view of Cassiopeia A, the remains of an exploded star located about 11,000 light-years from Earth. Over the years, Chandra’s views of Cassiopeia A have become some of the telescope’s best-known images.
      To mark the anniversary of this milestone, new sonifications of three images – including Cassiopeia A (Cas A) – are being released. Sonification is a process that translates astronomical data into sound, similar to how digital data are more routinely turned into images. This translation process preserves the science of the data from its original digital state but provides an alternative pathway to experiencing the data.
      Sonifications of three images have been released to mark the 25th anniversary of Chandra’s “First Light” image. For Cassiopeia A, which was one of the first objects observed by Chandra, X-ray data from Chandra and infrared data from Webb have been translated into sounds, along with some Hubble data. The second image in the sonification trio, 30 Doradus, also contains Chandra and Webb data. NGC 6872 contains data from Chandra as well as an optical image from Hubble. Each of these datasets have been mapped to notes and sounds based on properties observed by these telescopes.NASA/CXC/SAO/K.Arcand, SYSTEM Sounds (M. Russo, A. Santaguida) This sonification of Cas A features data from Chandra as well as NASA’s James Webb, Hubble, and retired Spitzer space telescopes. The scan starts at the neutron star at the center of the remnant, marked by a triangle sound, and moves outward. Astronomers first saw this neutron star when Chandra’s inaugural observations were released 25 years ago this week. Chandra’s X-rays also reveal debris from the exploded star that is expanding outward into space. The brighter parts of the image are conveyed through louder volume and higher pitched sounds. X-ray data from Chandra are mapped to modified piano sounds, while infrared data from Webb and Spitzer, which detect warmed dust embedded in the hot gas, have been assigned to various string and brass instruments. Stars that Hubble detects are played with crotales, or small cymbals.
      Another new sonification features the spectacular cosmic vista of 30 Doradus, one of the largest and brightest regions of star formation close to the Milky Way. This sonification again combines X-rays from Chandra with infrared data from Webb. As the scan moves from left to right across the image, the volume heard again corresponds to the brightness seen. Light toward the top of the image is mapped to higher pitched notes. X-rays from Chandra, which reveal gas that has been superheated by shock waves generated by the winds from massive stars, are heard as airy synthesizer sounds. Meanwhile, Webb’s infrared data show cooler gas that provides the raw ingredients for future stars. These data are mapped to a range of sounds including soft, low musical pitches (red regions), a wind-like sound (white regions), piano-like synthesizer notes indicating very bright stars, and a rain-stick sound for stars in a central cluster.
      The final member of this new sonification triumvirate is NGC 6872, a large spiral galaxy that has two elongated arms stretching to the upper right and lower left, which is seen in an optical light view from Hubble. Just to the upper left of NGC 6872 appears another smaller spiral galaxy. These two galaxies, each of which likely has a supermassive black hole at the center, are being drawn toward one another. As the scan sweeps clockwise from 12 o’clock, the brightness controls the volume and light farther from the center of the image is mapped to higher-pitched notes. Chandra’s X-rays, represented in sound by a wind-like sound, show multimillion-degree gas that permeates the galaxies. Compact X-ray sources from background galaxies create bird-like chirps. In the Hubble data, the core of NGC 6872 is heard as a dark low drone, and the blue spiral arms (indicating active star formation) are audible as brighter, more highly pitched tones. The background galaxies are played as a soft pluck sound while the bright foreground star is accompanied by a crash cymbal.
      More information about the NASA sonification project through Chandra, which is made in partnership with NASA’s Universe of Learning, can be found here. The collaboration was driven by visualization scientist Kimberly Arcand (CXC), astrophysicist Matt Russo, and musician Andrew Santaguida, (both of the SYSTEM Sounds project), along with consultant Christine Malec.
      NASA’s Universe of Learning materials are based upon work supported by NASA under cooperative agreement award number NNX16AC65A to the Space Telescope Science Institute, working in partnership with Caltech/IPAC, Center for Astrophysics | Harvard & Smithsonian, and the Jet Propulsion Laboratory.
      Chandra, managed for NASA by the agency’s Marshall Space Flight Center in partnership with the CXC, is one of NASA’s Great Observatories, along with the Hubble Space Telescope and the now-retired Spitzer Space Telescope and Compton Gamma Ray Observatory. It was first proposed to NASA in 1976 by Riccardo Giacconi, recipient of the 2002 Nobel Prize for Physics based on his contributions to X-ray astronomy, and Harvey Tananbaum, who would later become the first director of the Chandra X-ray Center. Chandra was named in honor of the late Nobel laureate Subrahmanyan Chandrasekhar, who earned the Nobel Prize in Physics in 1983 for his work explaining the structure and evolution of stars.
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      Europa Clipper Gets Set of Super-Size Solar Arrays
      NASA’s Europa Clipper spacecraft recently got outfitted with a set of enormous solar arrays at the agency’s Kennedy Space Center. Each measuring about 46½ feet long and about 13½ feet high, the arrays are the biggest NASA has ever developed for a planetary mission. They must be large so they can soak up as much sunlight as possible during the spacecraft’s investigation of Jupiter’s moon Europa, which is five times farther from the Sun than Earth is.
      NASA’s Europa Clipper is seen Aug. 21 at the agency’s Kennedy Space Center. Engineers and technicians deployed and tested the giant solar arrays to be sure they will operate in flight.NASA/Frank Michaux The arrays have been folded up and secured against the spacecraft’s main body for launch, but when they’re deployed in space, Europa Clipper will span more than 100 feet – a few feet longer than a professional basketball court. The “wings,” as the engineers call them, are so big that they could only be opened one at a time in the clean room of Kennedy’s Payload Hazardous Servicing Facility, where teams are readying the spacecraft for its launch period, which opens Oct. 10. 
      Meanwhile, engineers continue to assess tests conducted on the radiation hardiness of transistors on the spacecraft. Longevity is key, because the spacecraft will journey more than five years to arrive at the Jupiter system in 2030. As it orbits the gas giant, the probe will fly by Europa multiple times, using a suite of science instruments to find out whether the ocean underneath its ice shell has conditions that could support life.
      Powering those flybys in a region of the solar system that receives only 3% to 4% of the sunlight Earth gets, each solar array is composed of five panels. Designed and built at the Johns Hopkins Applied Physics Laboratory (APL) in Laurel, Maryland, and Airbus in Leiden, Netherlands, they are much more sensitive than the type of solar arrays used on homes, and the highly efficient spacecraft will make the most of the power they generate.
      NASA’s Europa Clipper is seen in a clean room at Kennedy Space Center after engineers and technicians tested and stowed the spacecraft’s giant solar arrays.NASA/Frank Michaux At Jupiter, Europa Clipper’s arrays will together provide roughly 700 watts of electricity, about what a small microwave oven or a coffee maker needs to operate. On the spacecraft, batteries will store the power to run all of the electronics, a full payload of science instruments, communications equipment, the computer, and an entire propulsion system that includes 24 engines.
      While doing all of that, the arrays must operate in extreme cold. The hardware’s temperature will plunge to minus 400 degrees Fahrenheit when in Jupiter’s shadow. To ensure that the panels can operate in those extremes, engineers tested them in a specialized cryogenic chamber at Liège Space Center in Belgium.
      “The spacecraft is cozy. It has heaters and an active thermal loop, which keep it in a much more normal temperature range,” said APL’s Taejoo Lee, the solar array product delivery manager. “But the solar arrays are exposed to the vacuum of space without any heaters. They’re completely passive, so whatever the environment is, those are the temperatures they get.”
      About 90 minutes after launch, the arrays will unfurl from their folded position over the course of about 40 minutes. About two weeks later, six antennas affixed to the arrays will also deploy to their full size. The antennas belong to the radar instrument, which will search for water within and beneath the moon’s thick ice shell, and they are enormous, unfolding to a length of 57.7 feet, perpendicular to the arrays.
      “At the beginning of the project, we really thought it would be nearly impossible to develop a solar array strong enough to hold these gigantic antennas,” Lee said. “It was difficult, but the team brought a lot of creativity to the challenge, and we figured it out.”
      Europa Clipper’s three main science objectives are to determine the thickness of the moon’s icy shell and its interactions with the ocean below, to investigate its composition, and to characterize its geology. The mission’s detailed exploration of Europa will help scientists better understand the astrobiological potential for habitable worlds beyond our planet.
      Managed by Caltech in Pasadena, California, NASA’s Jet Propulsion Laboratory leads the development of the Europa Clipper mission in partnership with APL for NASA’s Science Mission Directorate. APL designed the main spacecraft body in collaboration with JPL and NASA’s Goddard Space Flight Center. The Planetary Missions Program Office at NASA’s Marshall Space Flight Center executes program management of the Europa Clipper mission.
      NASA’s Launch Services Program, based at Kennedy, manages the launch service for the Europa Clipper spacecraft, which will launch on a SpaceX Falcon Heavy rocket from Launch Complex 39A at Kennedy.
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      Work is Underway on NASA’s Next-Generation Asteroid Hunter
      NASA’s new asteroid-hunting spacecraft is taking shape at NASA’s Jet Propulsion Laboratory. Called NEO Surveyor (Near-Earth Object Surveyor), this cutting-edge infrared space telescope will seek out the hardest-to-find asteroids and comets that might pose a hazard to our planet. In fact, it is the agency’s first space telescope designed specifically for planetary defense.
      Targeting launch in late 2027, the spacecraft will travel a million miles to a region of gravitational stability – called the L1 Lagrange point – between Earth and the Sun. From there, its large sunshade will block the glare and heat of sunlight, allowing the mission to discover and track near-Earth objects as they approach Earth from the direction of the Sun, which is difficult for other observatories to do. The space telescope also may reveal asteroids called Earth Trojans, which lead and trail our planet’s orbit and are difficult to see from the ground or from Earth orbit.
      A mirror that was later installed inside NASA’s Near-Earth Object Surveyor shows a reflection of principal optical engineer Brian Monacelli during an inspection of the mirror’s surface at the agency’s Jet Propulsion Laboratory on July 17.NASA/JPL-Caltech NEO Surveyor relies on cutting-edge detectors that observe two bands of infrared light, which is invisible to the human eye. Near-Earth objects, no matter how dark, glow brightly in infrared as the Sun heats them. Because of this, the telescope will be able to find dark asteroids and comets, which don’t reflect much visible light. It also will measure those objects, a challenging task for visible-light telescopes that have a hard time distinguishing between small, highly reflective objects and large, dark ones.
      “NEO Surveyor is optimized to help us to do one specific thing: enable humanity to find the most hazardous asteroids and comets far enough in advance so we can do something about them,” said Amy Mainzer, survey director for NEO Surveyor and a professor at the University of California, Los Angeles. “We aim to build a spacecraft that can find, track, and characterize the objects with the greatest chance of hitting Earth. In the process, we will learn a lot about their origins and evolution.”
      The spacecraft’s only instrument is its telescope. About the size of a washer-and-dryer set, the telescope’s blocky aluminum body, called the optical bench, was built in a JPL clean room. Known as a three-mirror anastigmat telescope, it will rely on curved mirrors to focus light onto its infrared detectors in such a way that minimizes optical aberrations.
      “We have been carefully managing the fabrication of the spacecraft’s telescope mirrors, all of which were received in the JPL clean room by July,” said Brian Monacelli, principal optical engineer at JPL. “Its mirrors were shaped and polished from solid aluminum using a diamond-turning machine. Each exceeds the mission’s performance requirements.”
      Monacelli inspected the mirror surfaces for debris and damage, then JPL’s team of optomechanical technicians and engineers attached the mirrors to the telescope’s optical bench in August. Next, they will measure the telescope’s performance and align its mirrors.
      Complementing the mirror assembly are the telescope’s mercury-cadmium-telluride detectors, which are similar to the detectors used by NASA’s recently retired NEOWISE (short for Near-Earth Object Wide-field Infrared Survey Explorer) mission. An advantage of these detectors is that they don’t necessarily require cryogenic coolers or cryogens to lower their operational temperatures in order to detect infrared wavelengths. Cryocoolers and cryogens can limit the lifespan of a spacecraft. NEO Surveyor will instead keep its cool by using its large sunshade to block sunlight from heating the telescope and by occupying an orbit beyond that of the Moon, minimizing heating from Earth.
      A technician operates articulating equipment to rotate NEO Surveyor’s aluminum optical bench – part of the spacecraft’s telescope – in a clean room at NASA’s Jet Propulsion Laboratory.NASA/JPL-Caltech The telescope will eventually be installed inside the spacecraft’s instrument enclosure, which is being assembled in JPL’s historic High Bay 1 clean room where NASA missions such as Voyager, Cassini, and Perseverance were constructed. Fabricated from dark composite material that allows heat to escape, the enclosure will help keep the telescope cool and prevent its own heat from obscuring observations.
      Once it is completed in coming weeks, the enclosure will be tested to make sure it can withstand the rigors of space exploration. Then it will be mounted on the back of the sunshade and atop the electronic systems that will power and control the spacecraft.
      “The entire team has been working hard for a long time to get to this point, and we are excited to see the hardware coming together with contributions from our institutional and industrial collaborators from across the country,” said Tom Hoffman, NEO Surveyor’s project manager at JPL. “From the panels and cables for the instrument enclosure to the detectors and mirrors for the telescope — as well as components to build the spacecraft — hardware is being fabricated, delivered, and assembled to build this incredible observatory.”
      Assembly of NEO Surveyor can be viewed 24 hours a day, seven days a week, via JPL’s live cam.
      The NEO Surveyor mission marks a major step for NASA toward reaching its U.S. Congress-mandated goal to discover and characterize at least 90% of the near-Earth objects more than 460 feet across that come within 30 million miles of our planet’s orbit. Objects of this size can cause significant regional damage, or worse, should they impact the Earth.
      The mission is tasked by NASA’s Planetary Science Division within the Science Mission Directorate; program oversight is provided by the Planetary Defense Coordination Office, which was established in 2016 to manage the agency’s ongoing efforts in planetary defense. NASA’s Planetary Missions Program Office at the agency’s Marshall Space Flight Center provides program management for NEO Surveyor.
      The project is being developed by JPL and is led by survey director Amy Mainzer at UCLA. Established aerospace and engineering companies have been contracted to build the spacecraft and its instrumentation, including BAE Systems, Space Dynamics Laboratory, and Teledyne. The Laboratory for Atmospheric and Space Physics at the University of Colorado, Boulder will support operations, and IPAC-Caltech in Pasadena, California, is responsible for processing survey data and producing the mission’s data products. Caltech manages JPL for NASA.
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      NASA Sets Coverage for Starliner Return to Earth
      NASA will provide live coverage of the upcoming activities for Boeing’s Starliner spacecraft departure from the International Space Station and return to Earth. The uncrewed spacecraft will depart from the orbiting laboratory for a landing at White Sands Space Harbor in New Mexico.
      Starliner is scheduled to autonomously undock from the space station at approximately 5:04 p.m. CDT Sept. 6, to begin the journey home, weather conditions permitting. NASA and Boeing are targeting approximately 11:03 p.m. Sept. 6 for the landing and conclusion of the flight test.
      The American flag pictured inside the window of Boeing’s Starliner spacecraft at the International Space Station.Credit: NASA NASA’s live coverage of return and related activities will stream on NASA+, the NASA app, and the agency’s website. Learn how to stream NASA programming through a variety of platforms including social media.
      NASA astronauts Butch Wilmore and Suni Williams launched aboard Boeing’s Starliner spacecraft on June 5 for its first crewed flight, arriving at the space station on June 6. As Starliner approached the orbiting laboratory, NASA and Boeing identified helium leaks and experienced issues with the spacecraft reaction control thrusters. For the safety of the astronauts, NASA announced on Aug. 24 that Starliner will return to Earth from the station without a crew. Wilmore and Williams will remain aboard the station and return home in February 2025 aboard the SpaceX Dragon spacecraft with two other crew members assigned to NASA’s SpaceX Crew-9 mission.
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