RFI - NNC13ZMX001L Page 1

Description:

The National Aeronautics and Space Administration (NASA) is seeking information through this Request for Information (RFI) to identify, improve and/or enhance approaches that will establish an initial cargo capability for the Space Launch System (SLS) Integrated Spacecraft and Payload Element. While emphasis in the responses should address existing available and current baseline 8.4 meter fairing approaches, alternate approaches may be suggested in order to consider all alternatives. This RFI is open to responses from all commercial and international entities. Sections 3-5 address key areas of information is being requested:

Section 3 - Adaptation of Existing Available Payload FairingsSection 4 - Adaptation of Existing Available Payload Adapters, andSection 5 - Development of an 8.4 Meter Fairing

Section 1: SLS Integrated Spacecraft and Payload Element Cargo Capability Overview

The primary goal of the SLS Integrated Spacecraft and Payload Element (ISPE) cargo capability is to provide affordable and flexible cargo carrying capabilities for the SLS consistent with NASA’s plan for exploration to augment the current crewed capability which delivers the Multi Purpose Crew Vehicle (MPCV) to orbit.

The Space Launch System (SLS) is the enabler for human deep space exploration. SLS will be capable of lifting the Orion MPCV, cargo and other exploration elements to Lagrange points, the moon, asteroids, and ultimately missions to Mars. It will expand scientific missions by enabling the launch of large robotic payloads.

RFI - NNC13ZMX001L Page 2

Section 2: SLS Integrated Spacecraft and Payload Element Cargo Capability RFI Response

Introduction: Respondents can submit information in response to the following three (3) sections in this RFI:

Section 3: Adaptation of Existing Available Payload FairingsSection 4: Adaptation of Existing Available Payload AdaptersSection 5: Development of an 8.4 Meter Fairing

Each section provides details for potential ISPE Cargo Capabilities and describes the information that is being requested. NASA is looking for existing and new capabilities to affordably develop and implement capabilities on future SLS cargo missions.

Request for Information: Responses must be submitted to:Timothy C. Pierce, Contracting OfficerGlenn Research CenterMS 60-121000 Brookpark RoadCleveland, Ohio 44135Timothy.C.Pierce@nasa.gov

Responses to this RFI shall be submitted in writing and electronic media postmarked no later than 5:00 PM EST on 21 December 2012.

The response must be sent as one printed hardcopy and electronically as single Microsoft Word .doc and/or Microsoft EXCEL .xls file for each response on a standard 700 MB CD (Compact Disk). Acceptable file types are Microsoft Office Word 2007 and Microsoft Office Excel 2007. For pictures, the Government prefers encapsulated Postscript (.eps) or embedded (copying and pasting any format of graphic into a document) MS Word 7.0 pictures. The following formats for pictures, drawings, figures, etc., are also acceptable: .cgm, .jpg, .wmf, .mpp, .dxf, or .bmp. Please use 11 point Times New Roman font where paragraphed, as well as single spaced pages printed one-sided.

For the purposes of this RFI, an Engineering Cost Estimate (ECE) is defined as a high-level single estimate without line item breakout or rates that provides an educated financial estimate to be reported in FY13 dollars.

Drawings have been provided in this RFI for clarification purposes, but are not intended to limit design space. All diagrams are notional mission concepts and subject to change.

RFI - NNC13ZMX001L Page 3

In addition to whatever information the responder chooses to provide, each RFI response shall include a cover sheet with the following information: 1. RFI Solicitation Number and Title 2. Responding Organization (including address, POC and phone number) 3. A brief synopsis of the RFI response in less than 20 words 4. Section number your response is addressing 5. Potential partnerships (industry, international, US government agencies) 6. Whether your company would be available for a site visit

This RFI is used solely for information planning purposes and does not constitute a solicitation. In accordance with FAR 15.201(e), responses to this RFI are not offers and cannot be accepted by the Government to form a binding contract. The Government is under no obligation to issue a solicitation or to award any contract on the basis of this RFI. The information provided in responses to this RFI will not be made public in an effort to protect any propriety company information. Nonetheless, respondents should clearly and properly mark any propriety or restricted data contained within its submission so it can be identified and protected. Respondents are solely responsible for all expenses associated with responding to this RFI. Responses to this RFI will not be returned, and respondents will not be notified of the result of the review.

Technical Points of Contact:

Sections 3 and 5:

Name: Joseph Roche

Title: Payload Fairing Manager

Email: Joseph.M.Roche@nasa.gov

Section 4:

Name: Jonathon C. McArthur (Craig)

Title: Spacecraft and Payload Integration Office deputy element manager

Email: J.Craig.McArthur@nasa.gov

RFI - NNC13ZMX001L Page 4

Acronyms

CD Compact Disk

CG Center of Gravity

DAC Design Analysis Cycle

dB decibels

ECE Engineering Cost Estimate

FAR Federal Acquisition Regulations

GSE Ground Support Equipment

ICPS Interim Cryogenic Propulsion Stage

ISPE Integrated Spacecraft and Payload Element

ISPERD ISPE Requirements Document

LH2 Liquid Hydrogen

LVSA Launch Vehicle Stage Adapter

Max-α Maximum Angle of Attack

Max-Q Maximum Dynamic Pressure

MPCV Multi-Purpose Crew Vehicle

NASA National Aeronautics and Space Administration

OASPL Overall Sound Pressure Level

PLF Payload Fairing

PSF Pounds per Square Foot

RFI Request For Information

SLS Space Launch System

RFI - NNC13ZMX001L Page 5

Section 3: Adaptation of Existing Available Payload Fairings

Description: NASA is evaluating cargo payload capabilities for initial Space Launch System (SLS) cargo missions. One alternative is to utilize an existing available payload fairing and adapt it as necessary. Figure 3-1 shows a conceptual 5 Meter (16.4ft) Class fairing adapted for SLS cargo missions. The information sought for this section is for fairings with a minimum diameter of 5m (16.4ft) up to a maximum diameter of 8.4m (27.6ft). In addition the fairing barrel length should be 10m (32.8ft) or greater. The fairing may interface directly to the top of the Interim Cryogenic Propulsion Stage (ICPS) Liquid Hydrogen (LH2) tank or to the top of the Launch Vehicle Stage Adapter (LVSA) depending on the most affordable approach to carry loads down through the vehicle. It is also desirable that the payload fairing be able to reduce external acoustic environments by 12 dB OASPL or greater.

The anticipated flight conditions have a Maximum Dynamic Pressure (Max-Q) of 800 pounds per square foot (PSF) using an angle of attack (Max-α) of +/-8 degrees, with a 2 g axial acceleration. In addition, the maximum acceleration condition is 5 g axial and 1.5 g lateral.

Figure 3-1 Conceptual Integrated Vehicle Fairing with 5 Meter Fairing

Available Fairing

Generic Payload

ICPS

LVSA

SLS Core Stage

RFI - NNC13ZMX001L Page 6

Information Sought:Contractors are requested to provide the information listed below.

Section 3 - Adaptation of Existing Available Payload FairingsNo. Information Sought3.1 Physical Characteristics

Description of existing payload fairings3.1.a a. Basic description (subsystem descriptions, e.g., separation, structures,

acoustics; mass, dimensions, and materials)3.1.b b. Anticipated modifications of fairing to meet SLS requirements3.1.c c. Graphical representation with overall dimensions3.1.d d. Payload static envelope (maximum payload dimensions/volume)3.1.e e. Stiffness/mass distribution (5 equidistant points along length of fairing starting

at the base); separation force applied between petals3.2 History3.2.a a. Flight success / failures3.3 Fairing separation system3.3.a a. Basic description (mass, dimensions, materials, functionality)3.3.b b. Pyrotechnic shock levels3.3.c c. Reliability of separation system3.3.d d. Standard minimum clearance criteria for separation system3.3.e e. Description of debris minimization for separation system.3.4 Description of launch vehicle interface3.4.a a. Structural3.4.b b. Mechanical3.4.c c. Electrical3.4.d d. Fluidic3.4.e e. Graphical representation with overall dimensions3.5 Design/Qualification Loads3.5.a a. Design Loads, factors of safety, and margins3.5.b b. Damage tolerance approach3.5.c c. List of Qualification Tests and Testing Levels3.6 Manufacturing3.6.a a. Manufacturing techniques and processes3.6.b b. Inspection techniques3.6.c c. Nominal manufacturing schedule3.7 Engineering Cost Estimates for Nominal Fairing3.7.a a. Design3.7.b b. Manufacturing3.7.c c. Qualification3.7.d d. Assembly3.7.e e. Logistics / Transportation3.7.f f. Total Fairing ECE3.8 Operations and Hardware Acceptance3.8.a a. GSE list3.8.b b. Handling processes and health monitoring3.8.c c. Repair approaches

RFI - NNC13ZMX001L Page 7

Section 3 - Adaptation of Existing Available Payload FairingsNo. Information Sought3.8.d d. Concept of Operations from Manufacturing through Launch3.9 Acoustic Attenuation Technology3.9.a a. List of potential technology to reduce external acoustic levels by 12 dB3.9.b b. Predicted/demonstrated technology performance3.9.c c. Technology maturity3.9.d d. Integration impacts of technology

RFI - NNC13ZMX001L Page 8

Section 4: Adaptation of Existing Available Payload Adapters

Description: Consistent with the evaluation of available payload fairings in the 5 Meter Class, NASA desires information on currently available payload adapters that can be used inside these fairings. As shown in Figure 4-1, the payload adapter should interface directly to the top of the Interim Cryogenic Propulsion Stage (ICPS).

The anticipated flight conditions have a Maximum Dynamic Pressure (Max-Q) of 800 pounds per square foot (PSF) using an angle of attack (Max-α) of +/-8 degrees, with a 2 g axial acceleration. In addition, the maximum acceleration condition is 5 g axial and 1.5 g lateral.

Figure 4-1 Generic Adapter Concept

RFI - NNC13ZMX001L Page 9

Information Sought:Contractors are requested to provide the information listed below.

Section 4 - Adaptation of Existing Available Payload AdaptersNo. Information Sought4.1 Physical Characteristics

Description of existing payload adapters4.1.a a. Basic description (subsystem descriptions, mass, dimensions, and materials)4.1.b b. Anticipated modifications of Payload Adapter to meet SLS requirements4.1.c c. Graphical representation with overall dimensions4.2 History4.2.a a. Flight record4.3 Payload separation system4.3.a a. Basic description (subsystem descriptions, mass, dimensions, materials,)4.3.b b. Pyrotechnic shock levels4.3.c c. Reliability4.3.d d. Description of debris minimization for separation system4.4 Description of launch vehicle interface4.4.a a. Structural4.4.b b. Mechanical4.4.c c. Electrical4.4.d d. Fluidic4.4.e e. Graphical representation with overall dimensions4.5 Description of payload interface4.5.a a. Structural4.5.b b. Mechanical4.5.c c. Electrical4.5.d d. Fluidic4.5.e e. Graphical representation with overall dimensions4.6 Design/Qualification Loads4.6.a a. General4.6.b b. Design Loads, factors of safety, and margins4.6.c c. Damage tolerance approach4.6.d d. List of Qualification Tests and Testing Levels4.6.e e. Load carrying capacity vs. payload center of gravity4.7 Manufacturing4.7.a a. Manufacturing techniques and processes4.7.b b. Inspection techniques4.7.c c. Nominal manufacturing schedule4.8 Engineering Cost Estimates for Nominal Payload Adapter4.8.a a. Design4.8.b b. Manufacturing4.8.c c. Qualification4.8.d d. Assembly4.8.e e. Logistics / transportation4.8.f f. Total Payload Adapter ECE4.9 Operations and Hardware Acceptance

RFI - NNC13ZMX001L Page 10

Section 4 - Adaptation of Existing Available Payload AdaptersNo. Information Sought4.9.a a. GSE list4.9.b b. Handling processes and health monitoring4.9.c c. Repair approaches4.9.d d. Concept of Operations from Manufacturing through Launch

RFI - NNC13ZMX001L Page 11

Section 5: Development of an 8.4 Meter Fairing

Description: NASA is evaluating cargo payload capabilities for Space Launch System (SLS) cargo missions using an 8.4m (27.6ft) diameter payload fairing. Figure 5-1 shows a 17.3m (56.6ft) non-separable lower fairing and separable upper fairing configuration. The fairing interfaces with the Interim Cryogenic Propulsion Stage (ICPS) which is mounted on top of the Launch Vehicle Stage Adapter.

It is also desirable that the payload fairing be able to reduce external acoustic environments by 12 dB OASPL or greater.

The requirements found in this document are a revised sub-set of those found in the SLS Integrated Spacecraft and Payload Element Requirements Document (ISPERD). Some of the requirements have been made intentionally generic where sufficient details do not yet exist to formulate more specific customer requirements (e.g. access door sizes, internal acoustic environment). Specific details are missing in some areas that are not required for sizing activities, but would be required in a mature design (vehicle and umbilical interfaces, for example). The purpose of this requirement set is to guide an overall structural sizing activity while taking into account some of the major penetrations and separation system reliability.

8.4 Meter Fairing Draft Requirements:

Figure 5-1 Conceptual Integrated Vehicle with 8.4 Meter Fairing

RFI - NNC13ZMX001L Page 12

The following requirements should be used when formulating your response:

The verb conventions used in these requirements are as follows:

• “Shall” – Used to indicate a requirement which must be implemented and its implementation verified in the design. • “Should” – Used to indicate good practice or a goal which is desirable. • “May” – Used to indicate permission. • “Will” – Used to indicate a statement of fact that is reflective of decisions or realities that exist.

FLIGHT EXTERNAL ENVIRONMENT

Aero LoadingThe flight conditions will have a Maximum Dynamic Pressure (Max-Q) of 800 pounds per square foot (PSF), using an angle of attack (Max-α) of +/-8 degrees, with a 2 g axial acceleration. In addition, the maximum acceleration condition will be 5 g axial and 1.5 g lateral.

Acoustic LevelsThe predicted maximum lift-off acoustic levels will be 156.9dB OASPL.

FAIRING OUTER MOLD LINE (OML)

Payload Fairing OML Diameter The PLF shall have an OML diameter of 8.4m (27.6ft).

Payload Fairing OML LengthThe PLF shall have an OML length not to exceed 36.4m (119.3ft).

PAYLOAD ACCOMODATION

Payload Fairing Envelope Volume The PLF shall provide a minimum internal available volume of 1,373.4m3 (48,500ft3).

Payload Fairing Dynamic Envelope DiameterThe PLF shall provide a minimum internal dynamic envelope diameter of 7.5m (24.6ft).

PLF Payload Access – Cargo DoorThe PLF shall accommodate payload access with a single (1) removable cargo door of 223.5cm (88in) (w) x 177.8cm (70in) (h) in the center of the PLF barrel section.

PLF Manned Payload Access – Man-Sized Door

RFI - NNC13ZMX001L Page 13

The PLF shall accommodate access to the payload compartment with two (2) removable man-sized access doors of 91.4cm (36in) x 91.4cm (36in) spaced within a 30 degree arc of the cargo door.

PAYLOAD ENVIRONMENT 

Payload Fairing Environmental ProtectionThe PLF shall protect the payload from natural environments from payload encapsulation, through launch vehicle ascent, to PLF separation.

Payload Fairing Environment MaintenanceThe PLF shall receive, distribute, and vent conditioned air or nitrogen from ground support systems while on the launch pad.

PERFORMANCE

Payload Fairing Separation ClearanceThe PLF shall maintain a minimum of 0.0508m (2in) of clearance from the payload and launch vehicle hardware at PLF separation.

Payload Fairing Separation ReliabilityThe PLF shall have a minimum reliability for successfully completing separation of 0.998.

LOGISTICS

Payload Fairing Vertical OrientationThe PLF will be used to only support vertical encapsulation.

Payload Fairing PartitioningThe PLF may be partitioned into multiple segments to accommodate encapsulation facility height restrictions.

DESIGN STANDARDS

PLF Technical Specifications and StandardsThe PLF shall comply with the intent of NASA-STD-5001A, Structural Design and Test Factors of Safety for Spaceflight Hardware, to the extent applicable. 

RFI - NNC13ZMX001L Page 14

Information Sought:Contractors are requested to provide the information listed below.

Section 5 - Development of an 8.4 Meter FairingNo. Information Sought5.1 Physical Characteristics

Description of potential 8.4 meter payload fairing5.1.a a. Basic description (subsystem descriptions, e.g., separation, structures, acoustics;

approximate mass and dimensions, materials)5.1.b b. Graphical representation with overall dimensions5.1.c c. Payload static envelope (maximum payload dimensions/volume)5.1.d d. Structural architecture and recommended materials5.1.e e. Identify key reliability drivers and reliability prediction methods for a new design5.2 History5.2.a a. Data from flight record that drives key trades and analyses and lessons learned5.3 Fairing separation systems5.3.a a. Basic description (include system redundancy)5.3.b5.3.c5.3.d5.3.e

b. Pyrotechnic shock levelsc. Reliability of separation systemd. Standard minimum clearance criteria for separation systeme. Description of debris minimization for separation system.

5.4 Conceptual Interface description5.4.a a. Structural5.4.b b. Mechanical5.4.c c. Electrical5.4.d d. Fluidic5.4.e e. Graphical representation with overall dimensions5.4.f f. Notional encapsulation interface and Concept of Operations5.5 Design/Qualification Loads5.5.a a. Design Loads, factors of safety, and margins5.5.b b. Damage tolerance approach5.6 Manufacturing5.6.a a. Manufacturing techniques and processes5.6.b b. Inspection techniques5.6.c c. Proposed manufacturing schedule5.7 Engineering Cost Estimates for Proposed Fairing5.7.a a. Design5.7.b b. Manufacturing5.7.c c. Qualification5.7.d d. Assembly5.7.e e. Logistics / transportation5.7.f f. Total fairing ECE5.7.g g. Identify cost reduction opportunities5.8 Operations and Hardware Acceptance5.8.a a. Handling processes and health monitoring5.8.b b. Concept of Operations from Manufacturing through Launch5.9 Acoustic Attenuation Technology

RFI - NNC13ZMX001L Page 15

Section 5 - Development of an 8.4 Meter FairingNo. Information Sought5.9.a a. Predicted/demonstrated technology performance5.9.b b. Technology maturity5.9.c c. Integration impacts of technology5.10 Risk Mitigation5.10.a a. Critical risk mitigation activities and rationale