I was wondering if anyone had explored the idea of creating a new shuttle orbiter that would interface with the current systems.
There has been a great deal of advancement in the past 34 years, since the last space shuttle was built. We have entirely new aerospace materials that are being widely used now including lithium aluminium and carbon fiber. We have far better computers and monitors with fiber optic communications. We have new materials for heat shields. We have more advanced sensor systems for detecting problems.
I also heard from an engineer that worked on the shuttle that the technology exists that would eliminate the necessity of disassembling the SSME after every flight thus reducing labor considerably.
I am not saying we should spend the money to do it, but it is an intellectual curiosity of mine.
There was an OV200 concept in the 90ies(or very early 2000). They would have either built new Orbiters or done a major upgrade on them.
The APU's which are very costly and dangerous would have been replaced by batteries and some of the shuttles hydraulics would have been replaced by electrical motors.
If a composite frame where used the shuttle's payload would have increased greatly.
The idea got no traction and after the Columbia accident NASA spun off in a different direction.
Major upgrades that did happen to the shuttle are:
1. Replacing the Original cockpit instruments with a glass cockpit saving both mass and electrical power. The Seats were lighted in that upgrade ET fuel tank was also lightened several times over the years.
2. Computer upgrades in the 90ies to bring the shuttle on par with a 486 computer.
3. Addition of Parachutes for landing.
4. A Orbiter extended duration kit that increased the amount of time the shuttle could stay in space. Originally Endeavor had it but it was removed from Endeavor and installed in Columbia(and later lost with it).They moved it to increase Endeavor's payload mass that it could carry to the station and gave it to Columbia because Columbia could not carry as much to the station as her sisters. In fact without the upgrades she received before her lost she could not have gotten to the ISS at all. Columbia for the most part would have focused on non ISS missions if not for the disaster but it could do a crew rotation and was planned to visit the ISS before her loss. Columbia could carry cargo to the ISS but it would have to be something small.
5. Plus an upgrade to the life support to use a regenerative CO2 removal to reduce the amount of LIOH cartridges needed(so the shuttle could stay more time in space with the same number of cartages).
6. A space station power system was also installed in all but Atlantis that allows the shuttle to us the ISS's power to extend the amount of time it can stay in space docked for a day or two.
7. Even in terms of Mass if built Enterprise would have been the heaviest shuttle. Columbia was the Heaviest, Challenger was a few hundred pounds lighter than Columbia and Discovery and Atlantis are about 2,000 pounds lighter than Columbia(when built). Some of the lightness was due to the use of Thermal blankets(in some areas) instead of all tile(like Columbia) and some structural changes.(Challenger as a test bed(OV99) showed some areas where over built).