Space Launch System Program Potential Enhancements

Space Launch System (SLS) is a joint effort of NASA and industry targeting exploration of the Moon, Mars, and beyond, under the Artemis program. SLS is a two stage LOX/LH₂ fueled rocket powered with four RS-25and RL-10 engines and augmented by two five segment solid rocket boosters (SRBs). Initial payload consists of Orion Crew and service module for transfer of astronauts to the surface of the Moon. November 17^th, 2022 marked the start of the Artemis 1 mission, successfully demonstrating the launch system. Orion successfully launched and performed circumnavigation of the moon with a safe return to Earth. Next generation of the SLS will require significant enhancements to maintain safety and increase affordability, sustainability, producibility, and payload performance. Potential further optimization of the propulsive stages promises to deliver mass savings. Major tasks could potentially be optimization of the primary and secondary structural components via further design refinement and optimization as well as material substitution. Aluminum Lithium alloy 2050, which is already a part of the new SLS Exploration Upper Stage (EUS), provides a potential opportunity for the Core Stage Intertank, LOX and LH₂ tankage. This advanced aluminum product offers a 5% density reduction with 30% higher strength and improved stress corrosion cracking resistance. In addition to potential structural material optimization, the SLS stages will be honing the technical performance and reliability of cryo-insulation systems that have been brought online since the Shuttle retirement. Safety, technical, and payload capability performance requires rigorous cryo-insulation process control.