The Space Shuttle's Southland Legacy
source: http://www.latimes.com/business/la-fi-shuttle-legacy-20110705,0,5978886,full.story
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The space shuttle's Southland legacy
The space shuttle program helped carry Southern California's aerospace industry for four decades, bequeathing new aeronautical technology — and jobs — to the local economy.
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PART ONE...
By W.J. Hennigan, Los Angeles Times
July 5, 2011
Bob Kahl slips in through a side door of the vast, abandoned hangar and looks at what's left of the assembly plant where he worked for nearly 40 years.
He remembers the hum of power tools, the biting aroma of cutting oil, swarms of workers plugging away on a labyrinth of yellow scaffolding. All that's left is a few piles of broken concrete and a sea of colorless dust that coats a Palmdale factory floor the size of two football fields.
"Welcome to the birthplace of America's space shuttle fleet," said Kahl, 60, smiling. "I never really thought it could come to this."
Photos: The shuttle's legacy in Southern California
Amid the odes to a shuttle program that ends with the last mission of the last shuttle, Atlantis, scheduled for liftoff Friday, is an awareness that the space plane helped carry Southern California's aerospace industry for four decades. It staved off decline after the end of the moon landings, bequeathing new generations of aeronautical technology — and jobs — to the regional economy.
"Building the space shuttle fleet enabled a historic chapter in NASA's space program," said NASA Administrator Charles Bolden, a former shuttle commander. "Southern California has a strong place in shuttle history as a key site where the spacecraft were built and often landed."
Constructing the shuttle fleet was testament to how advanced Southern California's aerospace engineering and labor workforce had become by the 1970s — and assured that the vast assemblage of brainpower and engineering know-how would not be lost in the Southland.
The history of the shuttle program may be linked forever to the flights of Challenger and Columbia, its two deadly tragedies. But the shuttle era will also be remembered for advancing technology, including reusable rocket engines and computerized guidance systems, that changed manned flight.
The shuttle is considered the world's most advanced flying machine because it blasted into space like a rocket, behaved in orbit like a floating laboratory, buzzed to and from the International Space Station with astronauts and supplies, and landed back on a runway like an airplane.
Before the shuttle, astronauts reached space by squeezing into a small capsule launched atop a massive rocket. By the time the shuttle was in design, the space program was looking for ways to keep as many as seven astronauts in orbit for weeks at a time in relative comfort.
To do this, scientists and engineers had to rethink nearly every aspect of the endeavor, notably flight controls, rocket engines and protection from searing heat generated by reentry.
"The shuttle was unlike anything that preceded it, so there were always new questions to answer," said Dwight Woolhouse, a shuttle engineer from the beginning of the program to this day.
The shuttle — large and aerodynamically unstable — needed sophisticated computer controls to guide the flight. The system, known as "fly by wire," is common on today's aircraft, but it was a rarity in flying machines in the 1970s. Engineers in Downey developed the computer-aided autopilot flight controls similar to today's systems that allow mammoth Boeing 747 jumbo jets to almost fly themselves.
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http://www.latimes.com/business/la-fi-shuttle-manufacturing-htm,0,4271845.htmlst...
California Connections...
Thousands of companies, from small manufacturers to aerospace giants, were involved in building and designing the space shuttle. The prime contractor was Rockwell International, based in Downey. Final assembly of the shuttles took place at a Rockwell plant in Palmdale.
Click on link (above) to view the various parts of the space shuttle built by the various builders.
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Click on the above link to view an interactive panorama...
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Panorama: The Canoga Park facility where the space shuttle engines were built
Bryan Chan / Los Angeles Times
The main engines for the space shuttles were made by Rocketdyne at this plant in Canoga Park. The vertical lathe was used to machine metal for large engine parts. The furnace was used to join metal parts for the shuttles and other rocket engines. In the welding room these nozzles, which have been used on several flights, will be installed on shuttles that are going on public display.
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Space shuttle's allure fostered a different breed of astronaut
The men and women who became shuttle astronauts lacked the star power of their 'right stuff' predecessors, but their accomplishments in and out of orbit were a giant leap forward.PHOTO: From left, American shuttle astronauts Charles Precourt and Dominic Gorie listen as Franklin Chang-Diaz speaks at a news conference at Florida's Kennedy Space Center after the return of Discovery. (Roberto Schmidt / AFP/Getty Images / June 12, 1998)
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Los Angeles Times...
By Ralph Vartabedian, Los Angeles Times
July 2, 2011, 7:02 p.m.
As a teenager in Costa Rica, Franklin Chang-Diaz had an improbable goal: becoming an American astronaut. Ultimately, he would fly a record seven shuttle missions and today wants to fly to Mars.Scott Parazynksi also wanted to go to space and figured becoming a doctor at Stanford University would help him get there. He became a jack-of-all-trades spacewalker, and went on to climb Mt. Everest and become chief of medicine and technology at a research hospital.
Curtis Brown Jr. dreamed of cockpits while growing up on a North Carolina tobacco farm. He became one of the shuttle's top pilots. Now, he flies airliners for a job and races jets over the Nevada desert for fun.
The blastoff of Atlantis in Florida on Friday will end not only the 30-year-old space shuttle program but also an era defined by a different, more driven breed of astronaut.
The 358 men and women NASA says became shuttle astronauts lacked the star power of their predecessors in the Mercury, Gemini and Apollo programs, who were made of the "right stuff" and walked on the moon. The shuttle astronauts' biggest headlines came in tragedy, when seven died in the 1986 explosion of Challenger and seven more perished in the fiery reentry breakup of Columbia in 2003.
But in many ways, what they accomplished before they walked into NASA, during their flights and in their careers afterward was a leap forward.
They were well-educated, physically fit, intellectually curious and diverse — men, women, blacks, Latinos and Asian Americans mingled in what before was an exclusive club.
The shuttle pilots flew orbiters above Earth with their hands on the thruster controls, delicately docking with the International Space Station and making no-second-chance landings on Earth. They walked in space scores of times, repairing the Hubble telescope and methodically assembling the space station from bits and pieces flown up in the shuttle's big trunk.
And their stories became much more a part of the common American fabric, even as they achieved something rarer than winning a lottery. The shuttle astronauts came from every corner of the nation and every background, and scattered in every direction when their space days ended.
Some were former combat pilots in the Vietnam War who took command of the shuttle cockpit, becoming known as the "bus drivers." Others were elite scientists in the back seats, conducting arcane experiments in orbit, and became known as "talking ballast."
They had one thing in common: After one flight, they became addicted and waited for years to get one more flight, and then another.
"It is an awe-inspiring emotional experience," said NASA Administrator Charles Bolden, a former shuttle commander who, like other astronauts, struggles to describe the sensation of launching atop a 60-story column of fire.
The best of the corps were super-achievers — setting their academic and career sights incomprehensibly high, forgoing better-paying professions to spend months rehearsing sometimes mundane tasks. Even among the best, a few stood out.
Chang-Diaz wanted to be an astronaut growing up in Costa Rica in the 1960s when he wrote to legendary rocket scientist Werner von Braun. NASA wrote back, suggesting he come to the United States to study engineering.
"I made up my mind that I would emigrate to the USA to follow my dream," he recalled.
The teenager went alone to Connecticut and by 1977 graduated from the Massachusetts Institute of Technology with a doctorate in plasma physics. He went on to have seven flights, a record he shares with Jerry Ross at the top of the astronaut pyramid. Today, Chang-Diaz, 61, is attempting to develop a revolutionary plasma rocket engine at his company, Ad Astra Rocket Co., that could reach Mars in a fraction of the time a conventional rocket would take.
Story Musgrave, who is the only astronaut to fly aboard all five shuttles and was the hands-on mechanic who fixed the Hubble Space Telescope, was perhaps the most highly educated of any astronaut. A chemist, mathematician, surgeon, biophysicist, business administrator and literary scholar by academic training, he has become a landscape contractor in Florida since leaving NASA.
"I own a bulldozer, a tree spade, two military dump trucks," said Musgrave, who flew six missions in all. "I do 20-acre projects. I was up in the cherry picker today trimming a tree."
Musgrave, 75, has a 5-year-old daughter, one of five children who range up to 50 years old. "Everybody's genes are different," he said.
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http://www.latimes.com/business/la-fi-nasa-green-20110531,0,4101016.story
NASA's Sustainability Base generates buzz for its eco-friendly architecture
The $20-million Silicon Valley office building, expected to be completed by mid-July, incorporates technology used by astronauts and will generate more electricity than it consumes..
ILLUSTRATION: An illustration shows the planned courtyard for NASA's Sustainability Base office building in Silicon Valley. The grass on the lawn will be irrigated with water from a contaminated groundwater treatment plant instead of drinkable water. Native plants have been placed on curved bioswales, or water-absorbing trenches, so their roots can filter contaminants out of rainwater before it enters storm drains. (William McDonough + Partners / May 31, 2011)
By Tiffany Hsu, Los Angeles Times
May 30, 2011, 8:01 p.m.
Reporting from Moffett Field, Calif.—Instead of sending its employees to space, NASA is building them an office of the future closer to home.
The curvy, space-age building at NASA's Ames Research Center in Silicon Valley incorporates technology used by astronauts and will be one of a few structures in the state that can generate more electricity than it consumes. Construction won't be complete until mid-July, but the federal government is already calling the $20-million facility its green building of the year.
It has a name only government officials could love — the Sustainability Base — but it is generating a lot of buzz among businesses and government agencies trying to be more green. The structure, near San Jose, was designed to be a model of eco-friendly architecture.
"Buildings of the future could actually produce more energy than they use and reverse the trend of being a big, sucking drain without compromising anything," said Steven Zornetzer, Ames' associate center director.
Compared to other office buildings of similar size, the Sustainability Base will be about 6% more expensive to construct, he said. But NASA expects to recoup the expense within a decade because the building will cost less to operate.
Executives from high-tech firms including IBM Corp. and Adobe Systems Inc. and the J. Craig Venter Institute have swung through the complex to get ideas for their own campuses. Constructing green buildings is gaining cachet for companies looking to cut energy costs while being environmentally chic.
The roughly 50,000-square-foot NASA building could help California rise in the ranking of states with eco-friendly commercial and institutional structures. It lags behind at least 10 other states, according to the U.S. Green Building Council. The group administers the Leadership in Energy and Environmental Design certification program, known as LEED.
Each part of the Sustainability Base performs some environmental function, said Zornetzer, who expects the building to score a platinum rating, LEED's highest level. "Nothing is just aesthetic."
The facility, on a formerly empty field, was designed by architectural firm William McDonough + Partners and AECOM and built by construction company Swinerton Inc. About 92% of the waste created during construction was either recycled or disposed in an environmentally friendly way and kept out of landfills. Steel and other materials were sourced from local vendors to help reduce emissions from transporting them.
The structure was designed to allow more natural light and air inside, where 220 NASA employees and contractors are expected to work. NASA also said its design would make it one of the safest structures in an earthquake.
Outside of the building, a fuel cell from Bloom Energy will create electricity from natural gas, though Zornetzer hopes to eventually use methane gas captured from landfills. Photovoltaic solar panels blanket the roof and patio umbrellas.
The grass on the lawn will be irrigated with water from a contaminated groundwater treatment plant instead of drinkable water. Native plants have been placed on curved bioswales, or water-absorbing trenches, so their roots can filter contaminants out of rainwater before it enters storm drains.
Technology used by astronauts captures used water from showers and sinks and treats it before sending it to urinals and toilets. The building will consume 90% less drinkable water than conventional buildings of comparable size.
Instead of noisy air-conditioning vents, the building's cooling will rely on an elaborate system of 5,000 light and carbon dioxide-measuring sensors. When the sensors determine the building is too warm, they will activate a nearby underground geothermal well system that helps pump water through copper tubing snaking through the ceiling. The liquid cools the surrounding air.
Depending on outside weather conditions, the building's central computer can open or close windows, adjust overhead lighting levels or raise and lower window shades. The building uses recycled glass, carpeting and furniture. The oak flooring was salvaged from a demolished wind tunnel facility.
Extensive skylights and reflective white walls mean that overhead lights will be needed for only 40 weekdays a year, NASA said.
In keeping with the building's green focus, NASA said its library will feature digital subscriptions to science and technology journals to cut down on paper.
"This is the 21st century," Zornetzer said. "You shouldn't build something that could've been built in 1990."
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PART THREE...
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At the program's peak in 1975, about 12,000 people, stretched over 120 acres in 40 buildings, were working in Downey on the shuttles. In the San Fernando Valley, 3,500 people worked at Rocketdyne. In Palmdale, the workforce hit 1,800. Thousands of others worked at supply firms.
"The shuttle program was so pervasive that it's hard to find an aerospace career employee in Southern California who did not have a hand in the project," said Gerald Blackburn, president of the Aerospace Legacy Foundation, a nonprofit organization of former aerospace employees who work to preserve Southern California's aerospace history.
There were environmental costs. Testing sites in both Canoga Park and Downey became subject to multimillion-dollar cleanups as a result of the space program.
But the shuttle's economic footprint didn't go away after the fleet was built. Although it was a much smaller operation than the original buildup, the Palmdale and Canoga Park sites later became high-tech Jiffy Lubes of sorts, servicing and upgrading shuttle technology.
That work continued after the space shuttle Challenger exploded after launch in 1986. After the space shuttle Columbia broke up during reentry in 2003, accident investigators concluded that the craft had "high inherent risks." Costs that averaged more than $1 billion per launch, according to independent researchers, also helped lead to the end of the shuttle program.
The Southern California aerospace industry has been preparing for more than a decade for the day when the shuttles were grounded for good. Boeing closed the former Rockwell plant in Downey in 1999. The remaining workforce has moved to Boeing's complex in Huntington Beach, and in June the company announced layoffs or reassignments for the last of its shuttle workers. In Canoga Park, the shuttle work at Rocketdyne — now part of Pratt & Whitney — will end this year.
But even as the space shuttle prepares to make its last venture into orbit, its technological progeny are growing and evolving into a new Space Age.
The men and women who built the shuttles, planned its science experiments, updated its hardware and guided it through space now have new assignments. Some have joined a new generation of engineers on burgeoning projects.
Boeing engineers in Huntington Beach are working to develop a seven-person spaceship that is designed to fly atop a variety of rockets and expects the spacecraft to be ready by 2015.
In Mojave, companies such as Scaled Composites and XCOR Aerospace Inc. are developing spacecraft to lift paying customers into outer space.
In Hawthorne, Space Exploration Technologies Corp., or SpaceX, plans to fill a $1.6-billion NASA contract for 12 flights to transport cargo to the International Space Station — a role that the space shuttle previously filled. The company's 18-story rocket that will power the missions, the Falcon 9, has made two flights to orbit, with a third slated for this year.
Former shuttle astronaut Garrett Reisman is working at SpaceX to develop the company's space capsule, dubbed Dragon, into a spaceship that can carry people, as well as cargo. The company aims to taxi astronauts to the space station for NASA by 2014.
"We're not reinventing the wheel here. We're just improving on technology that has come before," Reisman said. "The shuttle era is ending, and we're entering a period of transition. We're getting ready to step over a new threshold in human spaceflight."
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PHOTO: The Canoga Park (California) facility where the space shuttle engines were built.
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PART TWO...
PHOTO: The space shuttle Enterprise, a test orbitor that never flew into space, is carried by a 747 as takes off for its final test at Edwards Air Force Base on Oct. 27, 1977. (Joe Kennedy, Los Angeles Times / May 1, 2003)
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Another challenge was building rocket engines sturdy enough to work flight after flight for 55 missions. Before the shuttle, rocket engines were mostly one-of-a-kind chemistry sets — good for one flight only. The main engines, made by Rocketdyne in Canoga Park, helped propel the 2,250-ton shuttle assembly as high as 384 miles above Earth.
"We were wrestling with the technology at the time," said Robert Biggs, project engineer at Rocketdyne. "We had about 20 major accidents, but we finally got it right."
To keep the shuttle from burning up in the furnace-like heat upon reentry, new protection was developed. More than 30,000 silica ceramic tiles were individually contoured to the spaceship's body — like a jigsaw puzzle — dissipating heat around 2,300 degrees. The tiles, made by Lockheed Missiles & Space Co. in Sunnyvale, Calif., were key to the reusability of the shuttle.
Combined, the new technology would make space travel routine. There were 358 astronauts who reached outer space on the shuttle, whereas only 43 had gone before. The shuttle helped build the International Space Station, launched and later fixed the Hubble Space Telescope, and sent robotic probes to explore Venus, Jupiter and the sun.
During World War II, aircraft manufacturing boomed in California, with factories churning out war birds around the clock. After the war came to a close, the industry evolved from one centered around airplane manufacturing into one of cutting-edge engineering, groundbreaking science and high technology.
"Once the DNA code in aviation and aerospace was established in Southern California, it was unbreakable," Kevin Starr, a historian, author and USC professor, said in an interview.
After the World War II work dried up, the nation was caught in the Cold War and embarked to put a man on the moon during the Mercury, Gemini and Apollo programs.
But as the moon landings came to an end, the Southland's aerospace workforce was again at a crossroads. The four-decade-long shuttle program came at a crucial time. It provided the industry a bridge into the 21st century.
It was in Palmdale, at the edge of the Mojave Desert on the factory floor at Air Force Plant 42, that each of the shuttles — Enterprise, Columbia, Challenger, Discovery, Atlantis and Endeavour — came together for final assembly.
In addition to the major work in Downey and Canoga Park, parts of all sizes poured out of factories in California and across the nation.
The massive cargo bay, built to hold items as varied as satellites and pieces of the International Space Station, was manufactured by General Dynamics Corp. in San Diego. The landing gear struts that allowed the giant shuttle to gently touch down on a runway were built by Menasco Manufacturing Co. in Burbank. Hundreds of smaller shops made wire connectors, fuel valves and actuators — the parts that pulled everything together.
"It is the sort of program that helped build out the middle-class economic infrastructure in Southern California," Starr said. "It provided well-paying jobs to everybody from PhDs fresh out of Caltech all the way down to the line worker with a high school degree."
Robert G. Minor, former president of Rockwell Space Systems and now retired, recalled that the proposal to win the initial contract was 10,000 pages long and took more than a year to complete. "We knew what winning the program meant to the company and the region," he said. "Losing was not an option."
In 1972, North American Rockwell — later Rockwell International and now part of Boeing Co. — was named the primary contractor for the world's first reusable winged orbiting spaceship.
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