SA-500F (alternately SA500F, 500F, or Facilities Integration Vehicle) was a Saturn V used by NASA to test facilities at Launch Complex 39 at the Kennedy Space Center on Merritt Island, Florida throughout 1966. [1] Tests included the mating of the Saturn's stages in the Vehicle Assembly Building (VAB), the fit of the service platforms, the launcher-transporter operation, the propellant loading system, and the test connections to the mobile launcher and support equipment. [1]
Its three stages duplicated the flight configuration, ordnance, and umbilical connections of their live counterparts. Although inert, the retrograde rockets, ullage rockets, and shaped charges had the dimensions of the live ordnance to let the launch team practice ordnance installation. [2] The first stage only had one real F-1 engine, and the inter-tank section of the first stage had a different paint scheme than flight vehicles. The third stage had a paint scheme partially matching the Saturn 1B, for which it was originally made.
During its time as a test vehicle, SA-500F underwent several unique and critical evaluations to validate the facilities and procedures for the Saturn V program.
SA-500F was first stacked on Mobile Launcher 1 in the Vehicle Assembly Building High Bay 1 up to the Instrument Unit on March 30, 1966. The Apollo Command/Service Module facilities verification boilerplate was added on May 2, 1966. [3]
500F was rolled out to Pad A on May 25, 1966. On June 8, it was rolled back to the VAB temporarily as Hurricane Alma passed, though the ground crew supposed the rollback was more of an exercise than necessity because winds remained below critical for the entire storm. [4] 500F returned to Pad A on June 10. [5] Facility checkout culminated with a "wet test" (Filling the tanks with propellant) to verify storage and transfer of propellants. [2]
500F was removed from Pad A on October 14 and destacked on October 21, 1966. [5]
One notable test involved assessing the structural stability of the fully assembled rocket. Engineers manually rocked the Saturn V while it was stacked in the Vehicle Assembly Building (VAB), using ropes and their feet to simulate swaying motions. This unconventional method helped determine the vehicle's response to lateral forces and ensured the platform's stability during actual operations. [6]
On August 19, 1966, during a propellant loading test, a liquid oxygen (LOX) feed line ruptured, resulting in the loss of approximately 800,000 gallons of LOX. The rupture caused the inner shell of the LOX storage tank to collapse inward by 16 feet. The tank's shape was restored after re-pressurization, and the incident led to improved procedures for handling and transferring cryogenic propellants, ensuring safer operations in future launches. [6]
Following the successful completion of tests at Launch Complex 39A, there were tentative plans to reassemble SA-500F for similar facilities validation at Launch Complex 39B in the summer of 1967. However, these plans were never executed, as the objectives had already been achieved at Pad 39A, and program resources were redirected to other priorities in the Apollo schedule. [6]
These testing activities and their outcomes demonstrated the value of SA-500F as a non-flight facilities integration vehicle. The lessons learned contributed directly to the success of later Saturn V launches and the Apollo program as a whole.
SA-500F was the first complete assembly of something resembling a Saturn V, and model makers quickly patterned their designs after its paint scheme, but engineers changed the black stripe to white in the intertank section of the first stage for flight vehicles after discovering the intertank got too hot from the heat of the Sun. The third stage's paint scheme is similar to that of the Saturn IB, with some minor differences, since it was originally made for testing the facilities of the Saturn IB. Model manufacturers largely have not updated their paint schemes since. [7] [8] The SA-500D test article also had a similar paint scheme.
The first stage, S-IC-F, was returned to the Marshall Space Flight Center and was stored there for an extended time (possibly for a few years). The stage was eventually scrapped to make more room. [9] [10]
The second stage, S-II-F, was reassigned as a dynamic test stage at Marshall in early 1967 as S-II-F/D for use in the dynamic test vehicle SA-500D, after its predecessor was destroyed in an accident on a test stand. It is now displayed as part of the Saturn V at the U.S. Space & Rocket Center. [10]
The third stage, S-IVB-500F, was originally manufactured as a dummy third stage for the smaller Saturn IB and was used to fit-check the two Saturn IB launch complex facilities (LC 34 and LC 37). It was then modified to meet the Saturn V third stage configuration for use on the SA-500F. In 1970, it was modified into the Skylab Workshop Dynamic Test Stage [11] and was shipped in December to the Johnson Space Center for dynamic testing. In June 1971, it was shipped to Marshall for Skylab workshop static testing; and in June 1974 it was returned to KSC. [12] It was scrapped in the 1980s or 1990s, with a possible sighting in 1986. [13]
Apollo 4, also known as SA-501, was the uncrewed first test flight of the Saturn V launch vehicle, the rocket that eventually took astronauts to the Moon. The space vehicle was assembled in the Vehicle Assembly Building, and was the first to be launched from Kennedy Space Center (KSC) in Florida, ascending from Launch Complex 39, where facilities built specially for the Saturn V had been constructed.
The S-IVB was the third stage on the Saturn V and second stage on the Saturn IB launch vehicles. Built by the Douglas Aircraft Company, it had one J-2 rocket engine. For lunar missions it was fired twice: first for Earth orbit insertion after second stage cutoff, and then for translunar injection (TLI).
AS-201, flown February 26, 1966, was the first uncrewed test flight of an entire production Block I Apollo command and service module and the Saturn IB launch vehicle. The spacecraft consisted of the second Block I command module and the first Block I service module. The suborbital flight was a partially successful demonstration of the service propulsion system and the reaction control systems of both modules, and successfully demonstrated the capability of the command module's heat shield to survive re-entry from low Earth orbit.
AS-203 was an uncrewed flight of the Saturn IB rocket on July 5, 1966. It carried no command and service module, as its purpose was to verify the design of the S-IVB rocket stage restart capability that would later be used in the Apollo program to boost astronauts from Earth orbit to a trajectory towards the Moon. It achieved its objectives, but the S-IVB was inadvertently destroyed after four orbits during a differential pressure test that exceeded the design limits.
Saturn-Apollo 1 (SA-1) was the first flight of the Saturn I space launch vehicle, the first in the Saturn family, and first mission of the American Apollo program. The rocket was launched on October 27, 1961, from Cape Canaveral, Florida.
Saturn-Apollo 3 (SA-3) was the third flight of the Saturn I launch vehicle, the second flight of Project Highwater, and part of the American Apollo program. The rocket was launched on November 16, 1962, from Cape Canaveral, Florida.
Saturn-Apollo 5 (SA-5) was the first launch of the Block II Saturn I rocket and was part of the Apollo program. In 1963, President Kennedy identified this launch as the one which would place US lift capability ahead of the Soviets, after being behind for more than six years since Sputnik.
The Apollo spacecraft was composed of three parts designed to accomplish the American Apollo program's goal of landing astronauts on the Moon by the end of the 1960s and returning them safely to Earth. The expendable (single-use) spacecraft consisted of a combined command and service module (CSM) and an Apollo Lunar Module (LM). Two additional components complemented the spacecraft stack for space vehicle assembly: a spacecraft–LM adapter (SLA) designed to shield the LM from the aerodynamic stress of launch and to connect the CSM to the Saturn launch vehicle and a launch escape system (LES) to carry the crew in the command module safely away from the launch vehicle in the event of a launch emergency.
The Saturn IB was an American launch vehicle commissioned by the National Aeronautics and Space Administration (NASA) for the Apollo program. It uprated the Saturn I by replacing the S-IV second stage, with the S-IVB. The S-IB first stage also increased the S-I baseline's thrust from 1,500,000 pounds-force (6,700,000 N) to 1,600,000 pounds-force (7,100,000 N) and propellant load by 3.1%. This increased the Saturn I's low Earth orbit payload capability from 20,000 pounds (9,100 kg) to 46,000 pounds (21,000 kg), enough for early flight tests of a half-fueled Apollo command and service module (CSM) or a fully fueled Apollo Lunar Module (LM), before the larger Saturn V needed for lunar flight was ready.
The S-IC was the first stage of the American Saturn V rocket. The S-IC stage was manufactured by the Boeing Company. Like the first stages of most rockets, more than 90% of the mass at launch was propellant, in this case RP-1 rocket fuel and liquid oxygen (LOX) oxidizer. It was 42 m (138 ft) tall and 10 m (33 ft) in diameter. The stage provided 34,500 kN (7,750,000 lbf) of thrust at sea level to get the rocket through the first 61 km (38 mi) of ascent. The stage had five F-1 engines in a quincunx arrangement. The center engine was fixed in position, while the four outer engines could be hydraulically gimballed to control the rocket.
The Saturn I was a rocket designed as the United States' first medium lift launch vehicle for up to 20,000-pound (9,100 kg) low Earth orbit payloads. Its development was taken over from the Advanced Research Projects Agency (ARPA) in 1958 by the newly formed civilian NASA. Its design proved sound and flexible. It was successful in initiating the development of liquid hydrogen-fueled rocket propulsion, launching the Pegasus satellites, and flight verification of the Apollo command and service module launch phase aerodynamics. Ten Saturn I rockets were flown before it was replaced by the heavy lift derivative Saturn IB, which used a larger, higher total impulse second stage and an improved guidance and control system. It also led the way to development of the super-heavy lift Saturn V which carried the first men to landings on the Moon in the Apollo program.
The Space Shuttle external tank (ET) was the component of the Space Shuttle launch vehicle that contained the liquid hydrogen fuel and liquid oxygen oxidizer. During lift-off and ascent it supplied the fuel and oxidizer under pressure to the three RS-25 main engines in the orbiter. The ET was jettisoned just over 10 seconds after main engine cut-off (MECO) and it re-entered the Earth's atmosphere. Unlike the Solid Rocket Boosters, external tanks were not re-used. They broke up before impact in the Indian Ocean, away from shipping lanes and were not recovered.
The N1/L3 was a super heavy-lift launch vehicle intended to deliver payloads beyond low Earth orbit. The N1 was the Soviet counterpart to the US Saturn V and was intended to enable crewed travel to the Moon and beyond, with studies beginning as early as 1959. Its first stage, Block A, was the most powerful rocket stage ever flown for over 50 years, with the record standing until Starship's first integrated flight test. However, each of the four attempts to launch an N1 failed in flight, with the second attempt resulting in the vehicle crashing back onto its launch pad shortly after liftoff. Adverse characteristics of the large cluster of thirty engines and its complex fuel and oxidizer feeder systems were not revealed earlier in development because static test firings had not been conducted.
The Saturn V instrument unit is a ring-shaped structure fitted to the top of the Saturn V rocket's third stage (S-IVB) and the Saturn IB's second stage. It was immediately below the SLA (Spacecraft/Lunar Module Adapter) panels that contained the Apollo Lunar Module. The instrument unit contains the guidance system for the Saturn V rocket. Some of the electronics contained within the instrument unit are a digital computer, analog flight control computer, emergency detection system, inertial guidance platform, control accelerometers, and control rate gyros. The instrument unit (IU) for Saturn V was designed by NASA at Marshall Space Flight Center (MSFC) and was developed from the Saturn I IU. NASA's contractor to manufacture the Saturn V Instrument Unit was International Business Machines (IBM).
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The S-IB stage was the first stage of the Saturn IB launch vehicle, which was used for Earth orbital missions. It was an upgraded version of the S-I stage used on the earlier Saturn I rocket and was composed of nine propellant containers, eight fins, a thrust structure assembly, eight H-1 rocket engines, and many other components. It also contained the ODOP transponder. The propellant containers consisted of eight Redstone-derived tanks clustered around a Jupiter rocket-derived tank containing LOX. The four outboard engines gimballed to steer the rocket in flight, which required a few more engine components. The S-IB burned for nearly 2.5 minutes before separating at an altitude of 42 miles (68 km).
Launch Complex 39 (LC-39) is a rocket launch site at the John F. Kennedy Space Center on Merritt Island in Florida, United States. The site and its collection of facilities were originally built as the Apollo program's "Moonport" and later modified for the Space Shuttle program. Launch Complex 39 consists of three launch sub-complexes or "pads"—39A, 39B, and 39C—a Vehicle Assembly Building (VAB), a Crawlerway used by crawler-transporters to carry mobile launcher platforms between the VAB and the pads, Orbiter Processing Facility buildings, a Launch Control Center which contains the firing rooms, a news facility famous for the iconic countdown clock seen in television coverage and photos, and various logistical and operational support buildings.
The Saturn V dynamic test vehicle, designated SA-500D, is a prototype Saturn V rocket used by NASA to test the performance of the rocket when vibrated to simulate the shaking which subsequent rockets would experience during launch. It was the first full-scale Saturn V completed by the Marshall Space Flight Center (MSFC). Though SA-500D never flew, it was instrumental in the development of the Saturn V rocket which propelled the first men to the Moon as part of the Apollo program. Built under the direction of Dr. Wernher von Braun, it served as the test vehicle for all of the Saturn support facilities at MSFC.
The Saturn V is a retired American super heavy-lift launch vehicle developed by NASA under the Apollo program for human exploration of the Moon. The rocket was human-rated, had three stages, and was powered by liquid fuel. Flown from 1967 to 1973, it was used for nine crewed flights to the Moon, and to launch Skylab, the first American space station.
The S-I was the first stage of the Saturn I rocket used by NASA for the Apollo program.
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