1. Orbital Sciences Corporation (OSC) – Rensselaer Polytechnic Institute (RPI) – Cooperative Education Work Report
Rensselaer Polytechnic Institute i 2/9/2015
Cooperative Education Project Work Report
Rensselaer Polytechnic Institute
Testing and Integration of Sounding Rocket Payloads Overview
Duration: 11AUG14 – 19DEC14
Ray Parker1
Rensselaer Polytechnic Institute, Bachelor of Science, Chemical Engineering
Orbital Sciences Corporation, Wallops Flight Facility, Virginia 23337
Mentors: Robert Marshall2
, Philip Cathell3
1
Testing and Environmental Engineering Co-op, Chemical Engineering, Rensselaer Polytechnic Institute.
2
Testing and Environmental Engineering Lab Supervisor.
3
Mechanical Engineering Lead, Mechanical Engineering, Virginia Tech, Old Dominion University.

2. Orbital Sciences Corporation (OSC) – Rensselaer Polytechnic Institute (RPI) – Cooperative Education Work Report
Rensselaer Polytechnic Institute Page 1 12/10/2014
I. Overview
Orbital Sciences Corporation (Orbital ATK) is an industry leader in small and medium class space and rocket
systems. Orbital also supports human space flight by supplying commercial cargo resupply services for the
International Space Station using our new Antares® rocket and Cygnus™ cargo logistics spacecraft. In addition,
Orbital provides full service engineering, production and technical services for NASA, DoD, commercial and
academic space programs. Orbital also holds various commercial contracts, such as the NASA’s Commercial
Resupply Services (CRS) Contract and NASA’s Sounding Rocket Operations Contract (NSROC II).
In 2010, Orbital Sciences Corporation was selected by the National Aeronautics and Space Administration
(NASA) as the prime contractor role for the NASA Sounding Rocket Operations Contract II (NSROC II) program.
Under the NSROC II program, which is primarily centered at the NASA/GSFC, Wallops Flight Facility in Virginia,
Orbital’s Technical Services Division (TSD) is responsible for planning, coordinating, and carrying out sounding
rocket missions from locations in the U.S. and around the world. In addition, Orbital TSD is working with NASA to
develop and implement advanced sounding rocket capabilities to be used on the program. Sounding rockets are
smaller-sized launch vehicles that conduct suborbital missions for high-altitude scientific and atmospheric research.
Co-op Abstract. Under direct supervision by a senior testing and environmental technician or engineer,
perform specific engineering tasks of an analysis or test nature in a specialized engineering fields. Will
work to test and integrate sounding rocket payloads and various components and systems of spaceflight
sounding rocket technologies. Will collaborate with the Mechanical Engineering Department in the
Technical Services Division to help design and model hardware for future testing or integration. Apply
theoretical knowledge and engineering techniques to the solution of analytical engineering problems.
A. Key Deliverables at Project Completion:
1. Develop understandings of sounding rocket integration and testing timelines.
2. Aid in the design and modeling of multiple hardware components for the Mechanical Engineering
Department and develop an understanding of hardware manufacturing and assembly.
3. Develop a broad understanding of sounding rocket payload systems and suggestion modifications
and troubleshoot problems.
B. Key Learning:
1. Sounding rocket integration and testing timeline development.
2. Gain understanding of hardware and components that make up sounding rockets.
3. Understand manufacturing process and mechanical integration limitation.
The majority of sounding rocket flight hardware that is used at Wallops Flight Facility is tested in the Testing and
Environmental (T&E) Laboratory, run by Orbital Sciences. The lab consists of machinery and electrical devices that
are used to balance, vibrate, deploy, and bend test all sounding rocket payloads, and can also perform magnetic
calibration, and mass property analytics. The T&E Laboratory is a subsidiary of the Mechanical Engineering
Department which is overlooked by the Engineering Directorate underneath NSROC II Operations Management.
All sounding rocket payloads consist of scientific instruments or telescope, as directed by NASA. Each year
applications are sent out to academic institutions across the globe, of whom submit proposals with certain specialized
experiments designed to study sub-orbital space and high-atmospheric environments. Accepted proposals are then laid
out into the launch manifest. Launch can be achieved in as little as six months from design conception. Different
rocket payloads are split into different group classes with each payload being assigned a mechanical technician,
electrical technician, power engineering, electrical engineer, mechanical engineer, altitude control systems (ACS)
engineer and mission manager. This team takes the entire payload from the design stage to the final launch.
Scientific instrumentation and telescopes are the two main payloads launched by sounding rockets. Since sounding
rockets are much more simple than traditional medium-class orbital launch vehicles, they have a very quick turnaround
time (sometimes less than a month), much less expensive (sometimes as low as a million dollars), and allows for
repeatability of experiments and launches. When NASA puts a telescope (such as the Hubble Space Telescope, The
Great Observatories, etc.) into orbit, they require calibration and setting adjustments before they can begin taking
observations. In order to do this, NASA uses sounding rockets with identical lenses to put it into space momentarily,
allowing them to fine tune the settings of the satellite telescopes.

3. Orbital Sciences Corporation (OSC) – Rensselaer Polytechnic Institute (RPI) – Cooperative Education Work Report
Rensselaer Polytechnic Institute Page 2 12/10/2014
Most payloads consists of sub-payloads, stowaway booms and ampules that take sensitive measurements in high
atmospheric or space environments. These payloads are released by the launch vehicle at certain altitudes or variable
timing and are shot off by rockets, deployed by springs or pyrotechnics, or extended off the main body of the payload.
As an intern, some tasks and responsibilities that were required were to help in critical lift operations of various
flight hardware, including payloads/payload sections, palettes, vacuum chambers, various experiments and other
machinery. Additionally, torqueing joints and bolts, troubleshooting various problems within mechanical and
electrical systems, and helping to design and model various hardware components in Solidworks was done. The largest
responsibility expected of interns was aiding in the moving and testing of 10+ customized sounding rocket payloads,
through various test articles outlined below.
Sounding Rocket Flight Qualification Testing Concepts
Static and Dynamic Balance Testing
• During launch and takeoff, the launch vehicle spins in a counter-clockwise direction at a frequency between
two to five hertz, in order to maintain balance stability and directional accuracy during launch. Payloads must
be balanced beforehand in order for ACS and flight dynamic guidance to be maintained and ensure flight
mission assurance. Payload is place on a spin table with lead weights added on to pre-determined planes.
Sine and Random Vibration Testing
• In order to ensure payload durability during flight, the payload and components of the payload, need to be
tested beforehand on vibration machines. The payload is plugged into ground support equipment and then
vibrated with sine or random profiles. If no mechanical systems fail and ground support reads steadily and
reliably, the payload passes. Tests are usually over-simulated and natural frequencies may affect testing.
Bend Testing
• During flight, the payload is subjected to multiple high intensity bending moments, friction, compression and
tension forces. In order to ensure durability and mission assurance, V-Band joints are measured for
compliance. Testing consists of setting up dial indicators and bending by pushing and pulling via pneumatic
piston and measured by a load cell.
Mass Property Measurements Testing
• In order for ACS to perform properly, and flight performance predictions to be accurate, several mass
property measurements are needed, including pitch, roll and center of gravity of the payload. In order to do
so, each component and flight/launch configuration are needed to be measured for the Flight Performance
Department to ensure mission assurance during flight, as well as for ACS engineering. Each configuration of
the rocket is placed on a floating table with bearings that measure forces and moments for each configuration.
Operational Spin and Deployment Testing
• During or near apogee, the payload’s scientific objective usually occurs, which involves deployment of sub-
payloads/doors, science booms, nosecones and other devices. In order to ensure flight performance, testing
is done to ensure that pyrotechnics fire, releasing mechanisms without fail.
Magnetic Calibration Testing
• When the payload is guided to the correct trajectory or scientific instruments are determined by the Earth’s
magnetic field, the magnetometer of the payload must be calibrated using a specialized structure in order to
null out all other magnetic materials of the payload.
Ogive Recovery System Assembly
The O-give Recovery System
Assembly (ORSA), which includes a
parachute, is housed in the nosecone.
Experiments/Instruments
Provided by the researcher,
often from a University or
Government agency, to
collect data on the target
Attitude Control Systems (ACS)
Small jets expel gas to rotate the
payload in the desired direction. All
three axes, pitch, yaw and roll are
controlled.
Telemetry System
The TM transmits science
and vehicle data to a ground
station.
S19 Boost Guidance System
Most telescope payloads are launched
from sites with land impact areas and
are recoverable.
Aft Transition Section
The aft transition section is
used to mate two sections of
different diameters.
Table 1. Description of the main components of Sounding Rockets.
Figure 1. Model of a Black Brant IX Sounding Rocket

4. Orbital Sciences Corporation (OSC) – Rensselaer Polytechnic Institute (RPI) – Cooperative Education Work Report
Rensselaer Polytechnic Institute Page 3 12/10/2014
Centrifugal Testing
• Electronics and other payload components are tested using a medium size centrifuge. The centrifuge spins
for various RPMs for certain time intervals while the component is monitored to ensure flight durability.
Corona Testing
• Corona testing is done to verify transmitters and other electronics do not experience electrical arcing, or
coronal events, when they pass through the coronal region, typically 80,000 to 120,000 feet.
The goal for the duration of this co-op rotation was to help integrate and test sounding rockets and other various
types of space hardware in a safe and effective manner. Other objectives include helping the Mechanical Engineering
Department with various CAD and modeling projects.
II. Evaluation
In comparison to the job description and my expectations at OSC, I was pleased. I expected to be able to;
 Develop understandings of sounding rocket integration and testing timelines.
 Aid in the design and modeling of hardware components for the Mechanical Engineering Department.
 Develop an understanding of hardware manufacturing and assembly.
 Develop a broad understanding of sounding rocket payload systems.
 Sounding rocket integration and testing timeline development.
All of my goals have been met, besides being a contributor to a publication while on co-op; this may happen later
on. My mentor and all of the staff at Orbital and other contracting companies and organizations were very friendly
and accepting. I did not have many problems with people there. In addition to this, my colleagues that I share
laboratory and testing space with, have been very helpful in answering my questions and helping me to understand
certain rules and concepts. They have all given me suggestions on how to do things differently to improve my skills
as well as given me conceptual advice on what could be done more effectively while running tests and other concepts
in the Testing and Environmental Engineering Lab.
T&E Engineering Section Concepts
• Knowledgeable w/ various tools/machines
• Construction and basic ME fundamentals
• Vibration, Bend, and Balance test analysis
• Critical Lift Operations experience
• Fixture Installation
Software
• Solidworks 2014
• Adept for Solidworks
Mechanical Engineering Concepts
• Solidworks Modeling skills
• Solidworks Drawings and drafting
• Work document compilation
• Data mining for launch log book
Miscellaneous Concepts
• Electrical Engineering walk down
• Altitude Control System walk down
• Machine Shop walk down
No patents or honors/rewards were received. Various presentations may represent my work in the
future. Hardware will be in outer space though! Rensselaer’s Co-op Program has been very insightful
and has been a great learning experience. I am thankful for the opportunity to be able to go on co-op.
My only comment to make the co-op program better would be to have the monthly emails sent out on
time at the beginning of the month. I cannot think of
anything different.
Overall, my experience at Orbital Sciences
Corporation and NASA has been very interesting and
useful to my future. I have never thought that I would
be able to have a clear understanding of rockets or
launch vehicles work, or the basic process behind how
they are made and integrated. In addition to gaining an
understanding of the process, I’ve been able to help
accomplish important objectives with my colleagues
including successfully sending a couple of the rockets
that I worked on into space.Figure 2. Conde 52.001
after Deployment Testing Figure 3. Mechanical Technician and T&E Intern
unscrewing a Radax joint on Collins 46.009.