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Prepared by
GEORGE C. MARSHALL SPACE FLIGHT CENTER
OF
N A T I O N A L AERONAUTICS A N D SPACE ADMINISTRATION
Steps t o Satuhcl . . . . .
You could not tell exactly when the slow rise quickened. Suddenly,
the vehicle was rushing upward. Its speed increased and doubled, and in-
creased again, until the vehicle shrank to a brilliant orange dot in the south-
east sky.
This was the first flight test of the SATURN launch vehicle -- an
eight-engine booster capped with two inert stages and payload. T h e launch-.
ing will be followed by flights of nine other research and development
vehicles, some with a single live stage, some with two, and a few vehicles
with test versions of man-carrying spacecraft riding forward of the second
stage.
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By the end of these tests, after the measurements have been made and
improvements completed, we will have developed a new space vehicle t o
meet the objectives and programs of the national space effort. In perfecting
such a vehicle, we move one step closer to realizing certain of the national
space objectives -- to carry instruments, equipment, supplies, and living
organisms through space; to expand human knowledge of space; and to
preserve the role of the United States as a leader in peaceful space explora-
tion.
\
APOLLO, SPACECRAFT
Douglas Aircraft
OPERATIONS
WHITE BLOCKS.......PRINCIPAL INDUSTRIAL
T h e launch of the first SATURN was a public demonstration of
that detailed and sustained effort, on a national scale, begun little more
than three years before, in August 1958. Between design and launch, the
skills and talents of thousands of people were com.bined into a single
program, as fibers are combined to form a cord. People in management,
people in science, people in Government and industry -- all joining in a
coordinated effort to develop a new vehicle.
W e can see that effort quite clearly from the viewpoint of the
George C. Marshall Space Flight Center, manager of the S A T U R N program.
In mid-1960, the National Aeronautics and Space Administration gave the
Marshall Center responsibility for developing and launching NASA space
vehicles. SATURN was the largest and most demanding of these.
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J U P I T E R MISSILE, d e t w l o p e d b y p r e s e n t M S F C t e n m ,
e x t e n d e d t e c h n o l o g y o/ RliDSTONE program.
JUI’I?’ER is presenfly d e p l o y e d b y N A T O
Responsibility for major R&D programs has long been accepted
by members of Marshall. The Center is formed about a scientific and
management group that includes pioneers in rocketry and space research.
Supporting this group are engineers and technicians whose experience goes
back through JUPITER and REDSTONE to early United States' rocket
programs. T h e Center has also attracted many additional highly trained
people. Collectively, these individuals form an integrated organization of
widely diversified skills.
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S-IV STAGE
Aircraft
PROPELLANT CONTAINERS
Ling-Temco-Vought
s-I STAGE
Chrysler Corporatioi
- H-1 E N G I N E
Rocket dyne/
North American Aviation
Management of earlier research and development programs was,
comparatively, less complicated. Present management, in contrast, is se-
verely taxed by rapidly advancing technology and ever-expanding fields
of investigation. In this atmosphere of change, management must remain
flexible and informed by first-hand experience with the new tools of
science. This is particularly true of research and development, where
programs are based on principles recently discovered and technology
still being defined.
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Three main elements run like nerves through the SATURN pro-
gram: the launch vehicle, the ground support equipment, and the test
and launch facilities.
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These many events, so diverse and seemingly unrelated, advance
the vehicle program along carefully wrought schedules. Results of re-
search and development flow into the project. N e w technical appli-
cations are combined with proven techniques for each step in develop-
ment. By management direction, the three elements -- vehicle, ground sup-
port equipment, and facilities -- support and define each other, as work
moves forward along a broad front.
--
1 ) I V li I< S I : E V E N ' I ' S A 1) V A N C E '1'1 I I: V 13 111C I, E PI< O(;I< A A! I3 E LO IC': V P h i c la ra s p onse 1o
/ l i g h t c o n d i t i o n s is s i m u l n t c d in rlynnmir t p s t toirvr. F A C I N G P A G E . AI3OVE: Pro-
d u c t i o n o/ 11-1 e n g i n e s /or hoostcr; /jt?/,()\\'; Welding / u p 1 tank doma / o r S A T U R N
sacond stnge
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A V A I L A B L E ENGINE DESIGNS W E R E A D A P T E D F O R T H E B O O S T E R -- A B O V E : T H O R /
J U P I T E R ENGINE. Designs o/ this engine were used to accelerate development O /
S A T U R N booster H-1 engine, shown BELOW
To each problem, management responds with clear decisions: W e
will do this. W e will forego that. W e will go this way. Each decision
drives the program forward. Each decision leads to a more exact defi-
nition of vehicle performance.
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T A N K C L U S T E R I N G BEGINS -- D e s i g n s of RED.TTONE t a n k s (Foreground) a n d JU~'1'l'E'K
t a n k s (Background) were a d a p t e d /or the c l u s t e r e d booster
r(
c
INS'I'ALLATION O F H - 1 ENGINE -- D e s i g n a n a l y s i s a s s u r e s p r e c i s e mounting of e n g i n e s
on thrust structure
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All of this activity was paralleled by a program to develop the very
large I;-1 engine, intended for use in a future high-performance stage.
Design of this stage, however, began only after engine R&D was sub-
stantially complete, in order to secure maximum design experience. This
experience, in turn, served to shorten final stage development time.
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Every research and development program meets its share of un-
knowns, and SATURN is no exception to this rule. T h e very number of
problems encountered, as we extend technological and scientific frontiers,
requires the assistance of many participating organizations. Often the equip-
ment needed to study unusual technical problems is available at only
a few facilities. Or, perhaps, only a few individuals possess the specialized
skills and techniques required for certain investigations. Thus, in ad-
vancing development as efficiently and rapidly as possible, Marshall en-
lists the aid of many private and Government facilities. T h e work per-
formed by these facilities supplements research and development work
carried on by hlarshall’s operating divisions.
V E H I C L E D E V E L O P J l E N T P R O C E E D S ACROSS A BROAD F R O N T A T A V A R I E T Y O F
S P E C I A L I Z E D F A C I L I T I E S -- FAC1,VG P A G E : F a c i l i t y /or d e v e l o p m e n t o/ l i q u i d
hydrogen t e c h n o l o g y . AnOl’E: F - 1 e n g i n e turbopump t e s t s t a n d
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..
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Into the vehicle program comes a tidal surge of information: wind
tunnel investigations to determine aerodynamic responses. Studies of flame
pattern and heating in the booster tail section. New methods of sup-
pressing propellant slosh. Recovery of flight stages. Performance of low-
temperature propellants. Each research activity is reviewed and directed
by Marshall, for loss of tempo in a single study may be the cause o f a
slip in overall program schedules.
C t f E C K O U T EQUIPMENT P R O R E S V E I f l C L E S Y S T E M S --
N e w c h e c k o u t t e c h n i q u e s must b e d e v e l o p e d to m e e t
d e m a n d s of n e w v e h i c l e s y s t e m s
V A R I E D INDUSTRIAL FACILITIES S U P P O R T SATURN R C D -- A B O V E : T e s t mea for
c r y o g e n i c c o m p o n e n t s of l i q u i d hydrogen engines. BELOW: P r e s s u r e t e s t of s e a l e d
components
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V E H I C L E D E V E L O P M E N T IS A D V A N C E D BY TIIOUSANDS O F T E S T S - - F A C I N G P A G E :
Static t e s t o/ H - 1 e n g i n e ut contractor’s / n c i l i t y . RELOW’: C o l d / l o w t e s t i n g a t in-
dustrial l i q u i d hydrogen f a c i l i t y
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The same general method is used in formalizing booster design.
Marshall instruments and static fires a special test booster. Necessary
design changes and modifications are incorporated on the first flight
booster, which is then qualified for flight by its own short series of static
tests.
While the flight booster I S being fired, the special test booster is
modified to include further design improvements. T h e test sequence is
now repeated. T h e modified test booster is again static fired, and results
of these tests are used to improve the design of the second flight booster.
In this way, the latest findings of research and development are quickly
applied to flight hardwarc. The total numbcr of static firings is mini-
mized a n d devclopment time is correspondingly shortened.
For the greatest economy, many separate tests are made during
each booster firing. Name shield materials are evaluated at the same time
that techniques of engine ignition and shut-down are explored. Performance
of the propellant utilization system and control of engine movements are
stud i ed si m u I t a n eo ii s1y .
S T A T I C T E S T I N G BEGINS -- A SATURN booster i s p o s i -
tioned in Marshall’s static test stand for live firing
tests
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A s \\.e Ii;ivc seen, the myriad details o f appIied research and de-
v e l o 17m e n t t cs t i 11g a r e m o n it o red by hf a r sh a I 1' s tcc-li n i ca I d i v is i o n s. h 1a n ag e -
ment, howcver. clearly distinguishes M n r e e n responsibilities o f the di-
visions in their spccific areas, and the interdivisional work accomplished
by the technical working groups.
These groups directly link the Marshall Cei Ler with its contractors.
Fcr examp!e, at the beginning of the program to develop the SATURN
second stage, the S-IV Stage, Marshall formed working groups and in-
vited the contractor’s participation. These groups reviewed the s-IV design,
defining the proposed mating method, assuring that second stage systems
were compatible with those of the booster, and determining interface and
interstage requirements.
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The booster and S-IV Stage are joined by an interstage segment.
I n this area, the working groups resolve technical problems concerning
hoth the S-1 a n d S-IV design groups, Major rlcments invcstiptccj include
ae rod y namic 1oads, e I ec t rical connections, ph y s ica I mating , d i s po s i t io 11
of hydrogen gases prior to separation, and placement of ullage rockcts
(Lvhich give the stage sufficient forward motion, after separation, to
settle the propellant). As urork progresses on the stage, parallel studies
d e f i n e the designs o f r eq u i red ground SLIp po r t c1' u i p m e 11t a 11d I a LI n c 11
facilities.
T h e fuel for the S-IV Stage is liquid hydrogen. (Earlier decisions
have established that all SATURN upper stages will be powered with
liquid hydrogen-liquid oxygen engines.) Liquid hydrogen propulsion is
a relatively new field, thus far applied only to the ATLAS-CENTAUR
vehicle, and, in many areas, the technology is still being defined.
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I N T E G R A T E D T E S T PROGRAAIS D E F l N E PERFOK,\IANCE O F Ll Q U l l ) HYDROGEN - -
A B O V E : New i n s u l a t i o n s are f r s t d in s c a l r S-IV f n n k filled will) liquid hydrogen.
[?ELOW: C o n s t r u c t i o n of r l o u ~ ~ l e - u ~ n l lliquid
crl Iiydrogr?n s t o r a g e t a n k
1.
T o speed development of liquid-hydrogen propulsion, management
assures a maximum exchange of technical information between the CEN-
TAUR and the S-IV programs. Such information includes results of
cryogenic materials testing, special welding techniques, and design ap-
proaches to propellant utilization. Similar close-knit cooperation will exist
between the S-IV and the still more advanced S-I1 Stage, which is planned
for an advanced launch vehicle.
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Basic Marshall policy is to speed vehicle development by parallel
development of the stages. In keeping with this policy, engines for the
several SATURN stages are also developed simultaneously by contractors
who have demonstrated outstanding ability in the propulsion field. Through
this approach, development of the booster and its H-1 engines proceeds at
the same time. While the S-IV is under development, its RLlOA-3 engines
a x undergoing design 2nd test. -4s design planning continues for the S-11
Stage, its 1-2 engines are being developed. And, conciirrently with these
programs, the F-1 engine enters development testing, \vliile preliminary
design begins of an advanced booster stage which will use these engines.
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S-IV S T A G E T A N K A G E I S POSITIONED FOR P R O P E L L A N T LOADING T E S T S - S-IV
d e v e l o p m e n t t e s t i n g p a r a l l e l s e n g i n e and b o o s t e r d e v e l o p m e n t
t
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Characteristic of the approach used in coordinating these parallel
programs are the methods devised to integrate engines with the S-IV Stage.
Initially, inert engines are installed in a full-scale stage mockup to verify pro-
per fit and arrangement. Then prototype engines (the first fully functional
engines) are forwarded to the stage contractor; these engines are instaiied
to check control systems, mounting structures, the propellant flow system,
and for static firing tests. Finally, fully-developed engines are assembled
into the new stage for flight testing.
Similar methods are employed to integrate the S-IV Stage with the
S-I booster. A mockup of the S-IV is used to check functional and mechan-
ical mating with the interstage segment. In turn, the segment is fitted pre-
cisely to the s - I Stage. After development and tests of the s-IV are com-
pleted, the stage will be checked out, using equipment which electronically
simulates the booster stage and vehicle instrumentation. (After movement
of stages and payload to Cape Canaveral, the vehicle will be erected on the
launch pedestal and given a final exhaustive checkout before being com-
mitted to launch.)
C A R E F U L L Y ORGANIZED R A D A R NETWORK S U P P O R T S
SATURN PROGRAM -- V e h i c l e !light i s t r a c k e d by
interlocking radar i n s t a l l a t i o n s
By the time that booster flight tests are completed, the liquid-
hydrogen engines will be available for the s-IV Stage. T h e engines will
have been flight tested on the CENTAUR vehicle, and the great majority
of improvements made. Flight testing of the S-IV Stage will now begin.
During these tests, we will secure information concerning S-!V flight
operation, control, and in-flight separation. Additional checks will be
made of the tracking networks and launch facilities. At the same time,
the booster receives further flight trials, steadily increasing its reliability.
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The original launch schedules called for fliSht tests of another
upper stage, called the S-V, rather than the APOLLO spacecraft. T h e S-V
Stage? a slightly modified CENTAUR vehicle, was to be €light tested
immeclintely after tests of the live S-IV were completed.
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TO support APOLLO most effectively, Marshall is adding several
design improvements to the booster. Tanks are being lengthened to ac-
commodate a greater volume of propellants. Fins will be added to provide
increased vehicle stability. For an extra measure of control, the booster
engine swivel angle has been increased, and a more sensitive guidance
control system is being readied for thc manned mission.
F U L L - S C A L E MOCKUPS OF B L O C K I 1 V E H I C L E S T R U C T U R E S - - A B O V E : Instru-
ment unit will h o u s e g u i d a n c e and instrumentation equipment. BELOW: lnter-
stage connection and retrorockets
As this work progresses, scale models of the improved vehicle
undergo air flow and aerodynamic heating tests. Modified launch faciiity
designs allow for the booster’s tail fins and increased propellant require-
ments. While these activities proceed along a coordinated schedule, an
instrument unit is being developed for later Block I1 vehicles. Nerve
center of the entire vehicle, the instrument unit contains all guidance and
instrumentation required during flight. T h e unit, located just behind
the payload, will significantly improve the vehicle in-flight performance
and provide a test bed for guidance and other instrumentation being
developed for an advanced vehicle.
W I N D T U N N E L MODEL O F B L O C K I 1 V E H I C L E -- Many
s t u d i e s are performed t o de/ine v e h i c l e per/ormance
L A U N C H P E D E S T A L F O R B L O C K I1 VEHICLES - - D e s i g n s of ground support a n d launch
equipment reflect evolving vehicle design
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The SATURN program demands maximum flexibility and decisive-
ness by management. Rapid response to new needs is esse.ntial. T h e im-
mediate adjustment of the S A T U R N program to the APOLLO mission is
representative of Marshall’s swift technical reaction in an already complex
program. T h e capacity for immediate management response is now, as
in the past, based on the capabilities of Marshall’s operating divisions and
technical working groups.
V E H I C L E , S U P P O R T EQUIPMENT, A N D FACILITIES A R E
D E V E L O P E D ALONG INTEGRATED SCHEDULES --
FACING P A G E : LOX fill mast is tested at Marshall.
BELOW: Instrumentation developed for booster check-
out
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L A U N C l l FACILITIES A R F I I E S I G N E I ) T O AIEE?' TPEC1I:IC VBIIICIdP NEEDY --
AI3OVE: Aerial uierr, of S A T U R N L a u n c h C o m p l e x 34, C a p e Cannrrcral. I3FLOM':
IliRh-pressure pneurnatzc l i n e i n s t a l l a t i o n b r n c a t h u m b i l i c a l torrwr of the launch
complex
f A C I L I T l F S A 1 L A U N L l i L U l l P L F Y 34 -- 4 O O V E . Service structure ann' LOY storage
funk at LC-34. UELOll: F l a m e deflector nioues on r a d s to position heneoth launch
pedestal. seen in background
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S A T U R N LAU,VCII P E D E S 7 ' 4 L -- F o u r o / t I v Pighi arms support the iichicle prior to
li/to//; rpmnining nrrns rcstrnin iiehiclc n/ter ignition until n l f e n g i n e x r p n c b l u l l
s t a b l e burning, then drlrrm hock to r ~ f ~ nthe
s e vehicfe
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..
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While construction o f the first SATLJRN launch complex \vas
under\vay, hiarsliall began studies o f a second launch complex to support
operational firing rates. Designs o f the complex, including liquid-hydrogen
facilities, are based on the configuration o f the operational launch vehicle.
While this work progresses, planning begins for a launch cornplex which
will support advanced vehicles.
In the preceding pages, we have examined some of the major de-
cisions giving impetus and direction to the SATURN program. Marshall
has constantly balanced and coordinated program elements -- vehicle,
ground support equipment, facilities, and manned spacecraft effects --
along rigorously compressed development schedules. Each element requires
an intensive research and development effort, with a constant, sensitive
interplay maintained between the separate programs.
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('" - 3
g h e g c r h Side . . . . .
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T o carry out the booster production program, t\vo prime contractors
havc b e e n chosen. One \vi11 build and test thc operational first stage o f
the C-1 vehicle. T h e other contractor will develop and manufacture, in
production quantities, the F-I-powered booster for the advanced C-5
SATLJRN.
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t
~ h e s cnmJrrrtinn rn!2fis fcrrr: - - * c n C 2 !aigci paiteiii. Eevelopment
r - - --------
y L L L Vl.
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During the same period of time, research and development of the
advanced S-IVR Stage begins. To this program are brought the latest find-
ings of liquid-hydrogen technology. In this way. Marshall’s development
planning bears fruit -- each stage using liquid-hydrogen propulsion bene-
fits from the experience of its predecessors.
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ARTIST'S C O N C E P T OF T H E SATURN C-S LAUNCH V E H I C L E -- T h e v e h i c l e , measuring
? S O f e e t i n height, will lift o v e r 100 t o n s of p a y l o a d t o low earth orbit or e s c a p e
e a r t h ' s g r a v i t y w i t h 40-50 t o n s
-- The s i z e and
C O N C E P T O F RAIL-MOUNTED, V E H I C L E T R A N S P O R T E R - L A U N C H E R
weight o/ advanced launch vehicles place increased demands on designers of s u p p o r t
and launch equipment
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Tooling is adapted to meet the larger size and weight of the new
stages. Fabrication methods proven during the C-1 program are used to
develop improved methods of handling the thicker metals of the advanced
stages. Altered methods of assembly are devised -- assembly in the vertical
position, for instance, to prevent the stages from deforming through
their own \\eight. Checkout procedures are revised to suit new needs.
Automated checkout, at the factory, the test site, and the launch area, is
elaborated, step by step, from the findings of the present program.
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T h e sum of all this activity -- the experiments and tests and plans
driving forward in every section of the country -- is only a part o f the
program. There is more. T h e tempo of the program must be maintained.
Today is not soon enough to lay out plans for the still more advanced
vehicles of tomorrow.
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SOLID P R O P E L L A N T I3OOSTEK.T M A Y I3E C O M H I N E I ) lVlTll L I Q U I D P K O P E L I ~ A N ' I '
U P P E R S T A G E S -- Combination v e h i c l c s of t h i s t y p c c o u l d l i l t up t o 70 t o n s of
p a y l o a d on e s c a p e m i s s i o n s
C O N C E P T O F F U T U R E H E A V Y LAUNCH V E H I C L E
V e h i c l e s of t h i s t y p e , l a u n c h e d /I--- ---*L - - - I J
Inn,? d ~ n I r n c h a r o r r o l f o n mnnn a?
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This expansion has been planned as an orderly progression into
the regions beyond our planct. Each tcst contributes its share to the general
progress. 1’:ach stage increases vehicle capability. Each vehicle furthers per.
formancc of a mission, and each mission advances, one step further, the
national space effort.
Our sp;icc effort has steadily evolved towards ends \vhich can, at
prcscnt, be barely defined. This is to be expected. The f u l l impact o f
exploration lxyond natural boundaries cannot be determined all at once.
We met the same problem in the American expansion \vest. Then, the
cxplorcrs cnmc first to test out the ne\\‘ territory, to make direct contact
n i t h the country \ \ f a t , the land behind the river.
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