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By Space Force
A joint team of AFGSC Airmen launched an unarmed Minuteman III intercontinental ballistic missile equipped with a single Mark-21 High Fidelity Re-Entry Vehicle May 21 from Vandenberg SFB, Calif.
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By NASA
6 Min Read A Defining Era: NASA Stennis and Space Shuttle Main Engine Testing
The numbers are notable – 34 years of testing space shuttle main engines at NASA’s Stennis Space Center near Bay St. Louis, Mississippi, 3,244 individual tests, more than 820,000 seconds (totaling more than nine days) of cumulative hot fire.
The story behind the numbers is unforgettable.
“It is hard to describe the full impact of the space shuttle main engine test campaign on NASA Stennis,” Center Director John Bailey said. “It is hundreds of stories, affecting all areas of center life, within one great story of team achievement and accomplishment.”
NASA Stennis tested space shuttle main engines from May 19, 1975, to July 29, 2009. The testing made history, enabling 135 shuttle missions and notable space milestones, like deployment of the Hubble Space Telescope and construction of the International Space Station.
The testing also:
Established NASA Stennis as the center of excellence for large propulsion testing. Broadened and deepened the expertise of the NASA Stennis test team. Demonstrated and expanded the propulsion test capabilities of NASA Stennis. Ensured the future of the Mississippi site. The first space shuttle main engine is installed on May 8, 1975, at the Fred Haise Test Stand (formerly A-1). The engine would be used for the first six tests and featured a shortened thrust chamber assembly.NASA Assignment and Beginning
NASA Stennis was not the immediate choice to test space shuttle main engines. Two other sites also sought the assignment – NASA’s Marshall Flight Center in Alabama and Edwards Air Force Base in California. However, following presentations and evaluations, NASA announced March 1, 1971, that the test campaign would take place in south Mississippi.
“(NASA Stennis) was now assured of a future in propulsion testing for decades,” summarized Way Station to Space, a history of the center’s first decades.
Testing did not begin immediately. First, NASA Stennis had to complete an ambitious project to convert stands built the previous decade for rocket stage testing to facilities supporting single-engine hot fire.
Propellant run tanks were installed and calibrated. A system was fashioned to measure and verify engine thrust. A gimbaling capability was developed on the Fred Haise Test Stand to allow operators to move engines as they must pivot in flight to control rocket trajectory. Likewise, engineers designed a diffuser capability for the A-2 Test Stand to allow operators to test at simulated altitudes up to 60,000 feet.
NASA Stennis teams also had to learn how to handle cryogenic propellants in a new way. For Apollo testing, propellants were loaded into stage tanks to support hot fires. For space shuttle, propellants had to be provided by the stand to the engine. New stand run tanks were not large enough to support a full-duration (500 seconds) hot fire, so teams had to provide real-time transfer of propellants from barges, to the run tanks, to the engine.
The process required careful engineering and calibration. “There was a lot to learn to manage real-time operations,” said Maury Vander, chief of NASA Stennis test operations. “Teams had to develop a way to accurately measure propellant levels in the tanks and to control the flow from barges to the tanks and from the tanks to the engine. It is a very precise process.”
NASA Stennis teams conduct a hot fire of the space shuttle Main Propulsion Test Article in 1979 on the B-2 side of the Thad Cochran Test Stand. The testing involved installing a shuttle external fuel tank, a mockup of the shuttle orbiter, and the vehicle’s three-engine configuration on the stand, then firing all three engines simultaneously as during an actual launch.NASA Testing the Way
The biggest challenge was operation of the engine itself. Not only was it the most sophisticated ever developed, but teams would be testing a full engine from the outset. Typically, individual components are developed and tested prior to assembling a full engine. Shuttle testing began on full-scale engines, although several initial tests did feature a trimmed down thrust chamber assembly.
The initial test on May 19, 1975, provided an evaluation of team and engine. The so-called “burp” test did not feature full ignition, but it set the stage for moving forward.
“The first test was a monstrous milestone,” Vander said. “Teams had to overcome all sorts of challenges, and I can only imagine what it must have felt like to go from a mostly theoretical engine to seeing it almost light. It is the kind of moment engineers love – fruits-of-all-your-hard-labor moment.”
NASA Stennis teams conducted another five tests in quick succession. On June 23/24, with a complete engine thrust chamber assembly in place, teams achieved full ignition. By year’s end, teams had conducted 27 tests. In the next five years, they recorded more than 100 annual hot fires, a challenging pace. By the close of 1980, NASA Stennis had accumulated over 28 hours of hot fire.
The learning curve remained steep as teams developed a defined engine start, power up, power down, and shutdown sequences. They also identified anomalies and experienced various engine failures.
“Each test is a semi-controlled explosion,” Vander said. “And every test is like a work of art because of all that goes on behind the scenes to make it happen, and no two tests are exactly the same. There were a lot of knowledge and lessons learned that we continue to build on today.”
NASA Stennis test conductor Brian Childers leads Test Control Center operations during the 1000th test of a space shuttle main engine on the Fred Haise Test Stand (formerly A-1). on Aug. 17, 2006.NASA Powering History
Teams took a giant step forward in 1978 to 1981 with testing of the Main Propulsion Test Article, which involved installing three engines (configured as during an actual launch), with a space shuttle external tank and a mock orbiter, on the B-2 side of the Thad Cochran Test Stand.
Teams conducted 18 tests of the article, proving conclusively that the shuttle configuration would fly as needed. On April 12, 1981, shuttle Columbia launched on the maiden STS-1 mission of the new era. Unlike previous vehicles, this one had no uncrewed test flight. The first launch of shuttle carried astronauts John Young and Bob Crippen.
“The effort that you contributed made it possible for us to sit back and ride,” Crippen told NASA Stennis employees during a post-test visit to the site. “We couldn’t even make it look hard.”
Testing proceeded steadily for the next 28 years. Engine anomalies, upgrades, system changes – all were tested at NASA Stennis. Limits of the engine were tested and proven. Site teams gained tremendous testing experience and expertise. NASA Stennis personnel became experts in handling cryogenics.
Following the loss of shuttles Challenger and Columbia, NASA Stennis teams completed rigorous test campaigns to ensure future mission safety. The space shuttle main engine arguably became the most tested, and best understood, large rocket engine in the world – and NASA Stennis teams were among those at the forefront of knowledge.
NASA conducts the final space shuttle main engine test on July 29, 2009, on the A-2 Test Stand at NASA Stennis. The Space Shuttle Program concluded two years later with the STS-135 shuttle mission in July 2011.NASA A Foundation for the Future
NASA recognized the effort of the NASA Stennis team, establishing the site as the center of excellence for large propulsion test work. In the meanwhile, NASA Stennis moved to solidify its future, growing as a federal city, home to more than 50 resident agencies, organizations, and companies.
Shuttle testing opened the door for the variety of commercial aerospace test projects the site now supports. It also established and solidified the test team’s unique capabilities and gave all of Mississippi a sense of prideful ownership in the Space Shuttle Program – and its defining missions.
No one can say what would have happened to NASA Stennis without the space shuttle main engine test campaign. However, everything NASA Stennis now is rests squarely on the record and work of that history-making campaign.
“Everyone knows NASA Stennis as the site that tested the Apollo rockets that took humans to the Moon – but space shuttle main engine testing really built this site,” said Joe Schuyler, director of NASA Stennis engineering and test operations. “We are what we are because of that test campaign – and all that we become is built on that foundation.”
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Last Updated May 19, 2025 EditorNASA Stennis CommunicationsContactC. Lacy Thompsoncalvin.l.thompson@nasa.gov / (228) 688-3333LocationStennis Space Center Related Terms
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By NASA
During the Piston Powered Auto-Rama at the I-X Center in Cleveland on Monday, March 31, 2025, NASA Glenn Research Center’s Salvadore Oriti, right, discusses the technology behind free-piston Stirling cycle machines. Credit: NASA/Kristin Jansen NASA Glenn Research Center’s work in power and propulsion was on full display at the Piston Powered Auto-Rama at the I-X Center in Cleveland, March 28-30. The event is the largest indoor showcase of cars, trucks, motorcycles, tractors, and other engine-powered vehicles.
Center staff introduced guests to NASA’s Stirling engine technology, a free-piston Stirling power convertor that set records for accomplishing 14 years of maintenance-free operation at NASA Glenn in 2020. Attendees also explored how NASA is using space nuclear power to reach the deepest, dustiest, darkest, and most distant regions of our solar system through radioisotope power systems.
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By NASA
Technicians move the Orion spacecraft for NASA’s Artemis II test flight out of the Neil A. Armstrong Operations and Checkout Building to the Multi-Payload Processing Facility at Kennedy Space Center in Florida on Saturday, May 3, 2025. NASA/Kim Shiflett Engineers, technicians, mission planners, and the four astronauts set to fly around the Moon next year on Artemis II, NASA’s first crewed Artemis mission, are rapidly progressing toward launch.
At the agency’s Kennedy Space Center in Florida, teams are working around the clock to move into integration and final testing of all SLS (Space Launch System) and Orion spacecraft elements. Recently they completed two key milestones – connecting the SLS upper stage with the rest of the assembled rocket and moving Orion from its assembly facility to be fueled for flight.
“We’re extremely focused on preparing for Artemis II, and the mission is nearly here,” said Lakiesha Hawkins, assistant deputy associate administrator for NASA’s Moon to Mars Program, who also will chair the mission management team during Artemis II. “This crewed test flight, which will send four humans around the Moon, will inform our future missions to the Moon and Mars.”
Teams with NASA’s Exploration Ground Systems Program begin integrating the interim cryogenic propulsion stage to the SLS (Space Launch System) launch vehicle stage adapter on Wednesday, April 30, 2025, inside the Vehicle Assembly Building at NASA’s Kennedy Space Center in Florida. NASA/Isaac Watson On May 1, technicians successfully attached the interim cryogenic propulsion stage to the SLS rocket elements already poised atop mobile launcher 1, including its twin solid rocket boosters and core stage, inside the spaceport’s Vehicle Assembly Building (VAB). This portion of the rocket produces 24,750 pounds of thrust for Orion after the rest of the rocket has completed its job. Teams soon will move into a series of integrated tests to ensure all the rocket’s elements are communicating with each other and the Launch Control Center as expected. The tests include verifying interfaces and ensuring SLS systems work properly with the ground systems.
Meanwhile, on May 3, Orion left its metaphorical nest, the Neil Armstrong Operations & Checkout Facility at Kennedy, where it was assembled and underwent initial testing. There the crew module was outfitted with thousands of parts including critical life support systems for flight and integrated with the service module and crew module adapter. Its next stop on the road to the launch pad is the Multi-Payload Processing Facility, where it will be carefully fueled with propellants, high pressure gases, coolant, and other fluids the spacecraft and its crew need to maneuver in space and carry out the mission.
After fueling is complete, the four astronauts flying on the mission around the Moon and back over the course of approximately 10 days, will board the spacecraft in their Orion Crew Survival System spacesuits to test all the equipment interfaces they will need to operate during the mission. This will mark the first time NASA’s Reid Wiseman, Victor Glover, and Christina Koch, and CSA (Canadian Space Agency) astronaut Jeremy Hansen, will board their actual spacecraft while wearing their spacesuits. After the crewed testing is complete, technicians will move Orion to Kennedy’s Launch Abort System Facility, where the critical escape system will be added. From there, Orion will move to the VAB to be integrated with the fully assembled rocket.
NASA also announced its second agreement with an international space agency to fly a CubeSat on the mission. The collaborations provide opportunities for other countries to work alongside NASA to integrate and fly technology and experiments as part of the agency’s Artemis campaign.
While engineers at Kennedy integrate and test hardware with their eyes on final preparations for the mission, teams responsible for launching and flying the mission have been busy preparing for a variety of scenarios they could face.
The launch team at Kennedy has completed more than 30 simulations across cryogenic propellant loading and terminal countdown scenarios. The crew has been taking part in simulations for mission scenarios, including with teams in mission control. In April, the crew and the flight control team at NASA’s Johnson Space Center in Houston simulated liftoff through a planned manual piloting test together for the first time. The crew also recently conducted long-duration fit checks for their spacesuits and seats, practicing several operations while under various suit pressures.
NASA astronaut Christina Koch participates in a fit check April 18, 2025, in the spacesuit she will wear during Artemis II. NASA/Josh Valcarcel Teams are heading into a busy summer of mission preparations. While hardware checkouts and integration continue, in coming months the crew, flight controllers, and launch controllers will begin practicing their roles in the mission together as part of integrated simulations. In May, the crew will begin participating pre-launch operations and training for emergency scenarios during launch operations at Kennedy and observe a simulation by the launch control team of the terminal countdown portion of launch. In June, recovery teams will rehearse procedures they would use in the case of a pad or ascent abort off the coast of Florida, with launch and flight control teams supporting. The mission management team, responsible for reviewing mission status and risk assessments for issues that arise and making decisions about them, also will begin practicing their roles in simulations. Later this summer, the Orion stage adapter will arrive at the VAB from NASA’s Marshall Spaceflight Center in Huntsville, Alabama, and stacked on top of the rocket.
NASA astronauts Reid Wiseman (foreground) and Victor Glover participate in a simulation of their Artemis II entry profile on March 13, 2025.NASA/Bill Stafford Through Artemis, NASA will send astronauts to explore the Moon for scientific discovery, economic benefits, and build the foundation for the first crewed missions to Mars.
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By NASA
4 Min Read NASA Marshall Fires Up Hybrid Rocket Motor to Prep for Moon Landings
NASA’s Artemis campaign will use human landing systems, provided by SpaceX and Blue Origin, to safely transport crew to and from the surface of the Moon, in preparation for future crewed missions to Mars. As the landers touch down and lift off from the Moon, rocket exhaust plumes will affect the top layer of lunar “soil,” called regolith, on the Moon. When the lander’s engines ignite to decelerate prior to touchdown, they could create craters and instability in the area under the lander and send regolith particles flying at high speeds in various directions.
To better understand the physics behind the interaction of exhaust from the commercial human landing systems and the Moon’s surface, engineers and scientists at NASA’s Marshall Space Flight Center in Huntsville, Alabama, recently test-fired a 14-inch hybrid rocket motor more than 30 times. The 3D-printed hybrid rocket motor, developed at Utah State University in Logan, Utah, ignites both solid fuel and a stream of gaseous oxygen to create a powerful stream of rocket exhaust.
“Artemis builds on what we learned from the Apollo missions to the Moon. NASA still has more to learn more about how the regolith and surface will be affected when a spacecraft much larger than the Apollo lunar excursion module lands, whether it’s on the Moon for Artemis or Mars for future missions,” said Manish Mehta, Human Landing System Plume & Aero Environments discipline lead engineer. “Firing a hybrid rocket motor into a simulated lunar regolith field in a vacuum chamber hasn’t been achieved in decades. NASA will be able to take the data from the test and scale it up to correspond to flight conditions to help us better understand the physics, and anchor our data models, and ultimately make landing on the Moon safer for Artemis astronauts.”
Fast Facts
Over billions of years, asteroid and micrometeoroid impacts have ground up the surface of the Moon into fragments ranging from huge boulders to powder, called regolith. Regolith can be made of different minerals based on its location on the Moon. The varying mineral compositions mean regolith in certain locations could be denser and better able to support structures like landers. Of the 30 test fires performed in NASA Marshall’s Component Development Area, 28 were conducted under vacuum conditions and two were conducted under ambient pressure. The testing at Marshall ensures the motor will reliably ignite during plume-surface interaction testing in the 60-ft. vacuum sphere at NASA’s Langley Research Center in Hampton, Virginia, later this year.
Once the testing at NASA Marshall is complete, the motor will be shipped to NASA Langley. Test teams at NASA Langley will fire the hybrid motor again but this time into simulated lunar regolith, called Black Point-1, in the 60-foot vacuum sphere. Firing the motor from various heights, engineers will measure the size and shape of craters the rocket exhaust creates as well as the speed and direction the simulated lunar regolith particles travel when the rocket motor exhaust hits them.
“We’re bringing back the capability to characterize the effects of rocket engines interacting with the lunar surface through ground testing in a large vacuum chamber — last done in this facility for the Apollo and Viking programs. The landers going to the Moon through Artemis are much larger and more powerful, so we need new data to understand the complex physics of landing and ascent,” said Ashley Korzun, principal investigator for the plume-surface interaction tests at NASA Langley. “We’ll use the hybrid motor in the second phase of testing to capture data with conditions closely simulating those from a real rocket engine. Our research will reduce risk to the crew, lander, payloads, and surface assets.”
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Credit: NASA Through the Artemis campaign, NASA will send astronauts to explore the Moon for scientific discovery, economic benefits, and to build the foundation for the first crewed missions to Mars – for the benefit of all.
For more information about Artemis, visit:
https://www.nasa.gov/artemis
News Media Contact
Corinne Beckinger
Marshall Space Flight Center, Huntsville, Ala.
256.544.0034
corinne.m.beckinger@nasa.gov
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