Apollo picks up the pace

MOON ROCKET

On 19 January 1959 NASA took over the Air Force’s contract with Rocketdyne for the development of the F-1 kerosene-burning engine. The prototype was test fired on

10 February 1961. By sustaining 1.55 million pounds of thrust for several seconds, it broke the record for a single-chamber engine by a considerable margin. On 9 April 1961 it was announced that the engine had achieved 1.64 million pounds of thrust. On 26 May 1962 the engine was fired at full power for its intended operating time of 150 seconds. Meanwhile, Rocketdyne began the development of the 200,000-pound- thrust hydrogen-burning J-2 engine that was to power the upper stages of the Saturn launch vehicle. The first full-duration test of this engine was on 27 November 1963. The Douglas Aircraft Corporation fired an S-IVB stage utilising a single J-2 engine at full power for 10 seconds on a static rig at its Sacramento facility on 4 December 1964. But it was a ‘battleship’ variant (equivalent to a ‘boilerplate’ for a spacecraft) having tankage made of thick stainless steel instead of the lightweight aluminium of the operational vehicle. On 7 December 1964 the first S-IVB mockup – which was accurate in terms of mass, centre of gravity and structural stiffness, but with models of the engine and other systems – was delivered to the Marshall Space Flight Center for stress testing. On 16 April 1965 the first S-IC stage utilising five F-1 engines was test fired for several seconds at NASA’s Mississippi Test Facility. On 24 April the S-

11 stage utilising five J-2 engines was test fired at Rocketdyne’s facility at Santa Susana in California. On 5 August the S-IC made a full-duration test during which it responded to steering commands provided by the blockhouse. On 9 August the S-II made its first full-duration firing. That same day the first production version of the S-IVB was tested, and on 20 August it was fired for 3 minutes, shut down for half an hour and reignited for almost 6 minutes in a simulation of its role on a lunar mission.

Unfortunately, by early 1966 the development of the S-II had slipped. In an effort to recover, North American Aviation hired a new manager, Robert E. Greer, who took a team of engineers to the Mississippi Test Facility. On 23 April 1966 the S-II was successfully fired for 15 seconds, but faulty instrumentation caused premature

cutoffs on 10, 11 and 16 May. It fired for 150 and 350 seconds in tests on 17 and 20 May. But fires broke out in two places on the vehicle in a test on 25 May, and as the stage was being removed from the stand three days later its hydrogen tank exploded, damaging the facility and injuring five people. George Mueller in Washington began to send weekly progress reports on the S-II to company president Leland Atwood, at one point advising him that the S-II had an excellent chance of replacing the LM as the ‘pacing item’ in the program.

But then the fire that killed the Apollo 1 crew during a supposedly routine test of the spacecraft on 27 January 1967 halted the program in its tracks. Nevertheless, the time taken to redesign the CSM provided the opportunity for the development of the Saturn V and the LM to catch up.

On 17 April 1967 the Manned Spacecraft Center proposed a minimum of three manned Saturn V missions involving both the CSM and the LM prior to attempting the lunar landing. When George Mueller advocated landing on the third mission, Chris Kraft warned George Low that a landing should not be tried ‘‘on the first flight which leaves the Earth’s gravitational field’’ because flying to the Moon was such a great step forward in terms of operational capability that this should be demonstrated separately, to enable the landing crew to focus on activities associated with landing. Accepting Kraft’s argument, on 20 September Low led a delegation to Washington. Owen E. Maynard, Chief of the Systems Engineering Division in Houston, outlined a step-by-step sequence: (A) Saturn V and unmanned CSM development; (B) Saturn IB and unmanned LM development; (C) Saturn IB and manned CSM evaluation; (D) Saturn V and manned CSM/LM joint development; (E) CSM/LM trials in an Earth orbit involving a ‘high’ apogee; (F) CSM/LM trials in lunar orbit; (G) the first lunar landing; (H) further ‘minimalist’ landings; (I) reconnaissance surveys in lunar orbit; and (J) ‘enhanced capability’ landings.[48] This alphabetically labelled series was not a list of flights, as several flights might be required to achieve one mission. Two Saturn V development flights were already scheduled as Apollo 4 and Apollo 6, and the LM-1 flight as Apollo 5. Sam Phillips asked whether a second Saturn V test was really necessary, and Wernher von Braun said the second would serve to confirm the data from the first. If the Saturn V development were to prove to be protracted, then the ‘D’ mission would be done by reinstating the plan in which the CSM and LM would be launched individually by Saturn IBs and rendezvous in orbit. Most of the discussion was devoted to the proposal for a lunar orbital flight ‘‘to evaluate the deep space environment and to develop procedures for the entire lunar landing mission short of LM descent, ascent and surface operations’’. When Mueller argued ‘‘Apollo should not go to the Moon to develop procedures’’, Low said that developing crew operations would not be the

main reason for the mission; there was actually still a lot to be learned about navigation, thermal control and communications in deep space. Although the meeting left this matter undecided, the alphabetic labels soon became common shorthand.

Sam Phillips confirmed on 2 October 1967 that LM-2 should be configured for an unmanned test flight, and directed that LM-3 be paired with CSM-103 for the first manned mission of the complete Apollo configuration.2 Grumman’s latest schedule called for LM-2 to be delivered in February 1968, LM-3 in April and LM-4 in June. On 4 November George Mueller issued the schedule for 1968: AS-204 with LM-1; then AS-502 as the second unmanned test; AS-503 as the third unmanned test, if this proved necessary; AS-206 with LM-2, if required; AS-205 with CSM-101, manned; and AS-504 with CSM-103 and LM-3, manned. On 15 November George Low said that in the event of AS-503 being unmanned, the payload should be the ‘boilerplate’ spacecraft BP-30 and lunar module test article LTA-B.