<p><BR/>Replying to:<BR/><DIV CLASS='Discussion_PostQuote'>Well... If you "forget" the shuttle, Ares 1 consept is pretty direct derivate from earlier programs:Gemini, 1 person capsuleMercury, 2 person capsuleApollo, 3 person capsuleOrion, 4 person capsuleGot the picture? All of the programs have used the information from the earlier program. This is the case also with Ares. The only difference for Ares is that they have "proven shuttle hardware" which they are utilizing as booster stages (of course that heavily modified so it might not be so proven).Orion is a scaled up version of Apollo, like Apollo was scaled up version of Mercury. <br />Posted by Zipi</DIV></p><p>The problem with "utilizing proven shuttle hardware" is that they ARE NOT! Adding a fifth segment to the Shuttle SRB changes the whole design! The objective is to increase the thrust so the first stage (SRB) will lift the second stage and the Orion spacecraft. But when you add a fifth segment (or 5-1/2 in the case of the Ares V boosters), you increase the burning area of the propellant grain. This increases the pressure, so you must compensate by increasing the diameter of the nozzle throat. The increased throat diameter decreases the pressure, which is necessary to prevent bursting the case of the SRB. It also allows an increased mass rate of flow of the burning gases, which increases thrust.</p><p>An increased diameter throat also means an increase in the diameter of the diverging portion of the nozzle, which is going to increase the weight. It also means that the thrust vector control push rods that deflect the nozzle in the direction needed to steer the stack. This most likely means larger hydraulics packages and pushrods. Even if they go to some sort of electrical motors, the likelihood is increased mass.</p><p>The Shuttle stack, during the first 70 seconds of flight changes direction, especially roll, by moving the SRB nozzles differentially. But with a single SRB as the first stage, you have no differential roll control. So you have to add a roll thruster(s) to the first stage (SRB). That adds mass.</p><p>Then there is the Thrust Oscillation problem that is fairly common to all solid rocket motors, but is especially worrisome with the 5-segment rocket. NASA <em>thinks</em> it has a handle on that problem...by adding mass dampers, another 1200-1400 lbs (545.5 kg - 636 kg).</p><p>Then there is the second stage... The J-2X does build on Saturn V design. But, it uses a different turbopump setup, and is undergoing development as we "speak." It is NOT Shuttle derrived, of course.</p><p>So far as Orion is concerned, you seldom can "just scale up" a design like that. As I posted earlier, the original heat shield material is no longer made. Was its composition proprietary? I don't know, but as MeteorWayne posted the plans and specifications no longer exist (or if they do, NASA hasn't been able to find them!!!).</p><p>Hopefully, America's space program will continue dispite the economic crisis in America. In the worst case, the whole question of keeping ISS accessible to U.S. astronauts, manned explanation of the Moon and then on to Mars, could be cancelled by a vote in Congress, or by the next President, whoever he may be. Most likely, it will limp along. Hopefully, Congress and the President will see the light, that a vigorous space program (including manned space beyond LEO) provides jobs, accelerated technological development and maintains America's leadership in the space program.</p><p>Ad LEO! Ad Luna! Ad Ares! Ad Astra!</p><p> </p>