Cracks have been found in the first Orion capsule intended to fly in space.
Government space marches on! Cracks have been found in the first Orion capsule intended to fly in space.
The cracks were discovered during a proof pressure test the week of Nov. 5. Proof testing, in which a pressure vessel is subject to stresses greater than those it is expected to encounter during routine use, is one of the many preflight tests NASA is performing on Orion to certify the craft is safe for astronauts, agency spokeswoman Rachel Kraft said. “The cracks are in three adjacent, radial ribs of this integrally machined, aluminum bulkhead,” Kraft wrote in an email. “This hardware will be repaired and will not need to be remanufactured.”
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Government space marches on! Cracks have been found in the first Orion capsule intended to fly in space.
The cracks were discovered during a proof pressure test the week of Nov. 5. Proof testing, in which a pressure vessel is subject to stresses greater than those it is expected to encounter during routine use, is one of the many preflight tests NASA is performing on Orion to certify the craft is safe for astronauts, agency spokeswoman Rachel Kraft said. “The cracks are in three adjacent, radial ribs of this integrally machined, aluminum bulkhead,” Kraft wrote in an email. “This hardware will be repaired and will not need to be remanufactured.”
Readers!
Please consider supporting my work here at Behind the Black. Your support allows me the freedom and ability to analyze objectively the ongoing renaissance in space, as well as the cultural changes -- for good or ill -- that are happening across America. Fourteen years ago I wrote that SLS and Orion were a bad ideas, a waste of money, would be years behind schedule, and better replaced by commercial private enterprise. Only now does it appear that Washington might finally recognize this reality.
In 2020 when the world panicked over COVID I wrote that the panic was unnecessary, that the virus was apparently simply a variation of the flu, that masks were not simply pointless but if worn incorrectly were a health threat, that the lockdowns were a disaster and did nothing to stop the spread of COVID. Only in the past year have some of our so-called experts in the health field have begun to recognize these facts.
Your help allows me to do this kind of intelligent analysis. I take no advertising or sponsors, so my reporting isn't influenced by donations by established space or drug companies. Instead, I rely entirely on donations and subscriptions from my readers, which gives me the freedom to write what I think, unencumbered by outside influences.
You can support me either by giving a one-time contribution or a regular subscription. There are four ways of doing so:
1. Zelle: This is the only internet method that charges no fees. All you have to do is use the Zelle link at your internet bank and give my name and email address (zimmerman at nasw dot org). What you donate is what I get.
2. Patreon: Go to my website there and pick one of five monthly subscription amounts, or by making a one-time donation.
3. A Paypal Donation or subscription:
4. Donate by check, payable to Robert Zimmerman and mailed to
Behind The Black
c/o Robert Zimmerman
P.O.Box 1262
Cortaro, AZ 85652
You can also support me by buying one of my books, as noted in the boxes interspersed throughout the webpage or shown in the menu above.
Where is joe?
this thing will never fly. its a big caper designed to funnel money into what they Really want or have. and, at best, this thing is nearly 50 years out of date. what a shameful Scam !
Why did they drop forge and CNC mill out HUGE portions of the frame?
They could have just as easily welded up the very same thing for FAR less cost and I bet the same weight and size.
They found cracks in the frame already and they are now welding them back together. Which is harder to do on DF, or hammer forged, CNC milled pieces. Metal densities are different from the normally welded, rolled or extruded material.
Seriously this whole program is just engineers playing games trying to get their own pet projects into the machine for no real reason than to say they did.
Just like they have done for the last fifty years.
They need to realize NASA is no longer their own research facility with unlimited funds.
Could you define some terms for me so I can better understand what you are saying? For example, what does CNC stand for? Similarly, what is DF? And can you describe both? Also, what is “drop forge”?
I suspect I understand you, and I also believe that if I do you are completely correct, that Lockheed choose a much more expensive way to build Orion then necessary. However, I just want to understand a bit better what you are talking about. I am not an engineer, but I do make my living translating the jargon of scientists and engineers into plain English.
CNC= Computer numeric Control Basically a computer is running the milling machine following a predetermined design. They make small ones for small shops and even home size models.
Drop forging and hammer forging are the same thing. You take hot metal and smash it into the die to give it a shape. But in one process hammer forging is used to just smash the hot metal into a smaller area or shape. Driving out contaminates and any air pockets thus forcing the density of the metal higher.
The metal parts of JIM suits ( http://en.wikipedia.org/wiki/JIM_suit ) are hammer forged as one huge piece and then CNC milled out of it.
Running the metal through rollers drawing it out into a longer shape does almost the same thing in raising its density. Except rolling mills are WAY cheaper. You get flat stock this way. http://en.wikipedia.org/wiki/Rolling_%28metalworking%29
Extruding metals like aluminum even cheaper. Just pushing hot metal through a shaped die to give it a complex shape. Like running boards for trucks and vans or window frames.
They could have CNC milled out a few of the smaller real complex shapes(like rounded corners and window or door frames.) and used cheaper processes to make the rest less complex areas. Welding the whole thing together in the end.
We don’t machine out of one large piece of metal fighter plane frames. Why would this thing need to be? Is it taking higher G’s or more damage?
Every metal working company out there gives away catalogs of premade shapes they can put out inside of 24 hours.. All they need do is open up the book from an aluminum company and find the shape They can order and size and shape they need. They can also order the exact density, hardness and rigidity.
They had a range of specifications that would have been acceptable or workable and they took the top of the list because cost and time mean nothing to them. Its not their money.
Thank you for the information. It confirms what I thought, that Lockheed Martin chose to build Orion the most expensive way possible because, as you say, “It’s not their money.”
While a manned capsule hitting the atmosphere at 25,000 mph after returning from the Moon probably experiences higher G’s and greater stress than a jet fighter, I suspect they easily could have welded much of the capsule to save money. For example, take a close look at the Gemini capsule flown in the mid-1960s. It appears they even used rivets to assemble the thing’s outside shell!