Firefly identifies cause of first stage explosion during static fire test in September
The Alpha first stage, prior to September explosion
Firefly yesterday announced it has completed its investigation into the explosion during a static fire test in September that destroyed the first stage of the Alpha rocket during final preparations prior to launch.
Following a thorough review of the Alpha Flight 7 first stage ground test on September 29, Firefly identified a process error during stage one integration that resulted in a minute hydrocarbon contamination, which then led to a combustion event in one of the engines during the ground test. The test stand structure remained intact and no other facilities were impacted.
…Firefly immediately took action and implemented corrective actions, which included increasing inspection requirements for the fluid systems, optimizing the first stage sensors, and incorporating additional automated aborts. Firefly also implemented key process improvements following a daylong quality stand down where the production, integration, and test teams conducted exercises to review and optimize existing procedures. As part of Firefly’s effort to improve reliability and quality, the team will continue to hold regular exercises for sustained process enhancements.
The company also said the problem was not a design issue with the rocket.
It appears from the company’s press release that the contamination occurred because of a work force quality control issue, that required a major daylong review by all their employees to make sure their operations in building the stage would be more rigorous going forward.
The plan now is to pull another first stage from the company’s production line and stack that with the original upper stage. The target date for launch is late this year or early next year, “depending on range availability.”
Firefly had hoped to do five launches in 2025. At this moment it has only attempted one, in April, which failed. That investigation took until mid-September to complete. The next launch attempt was then delayed by the first stage explosion.
I imagine the company very much wants to get at least one launch off this year. I also imagine it is aggressively reviewing its rocket work force due to these issues.
On Christmas Eve 1968 three Americans became the first humans to visit another world. What they did to celebrate was unexpected and profound, and will be remembered throughout all human history. Genesis: the Story of Apollo 8, Robert Zimmerman's classic history of humanity's first journey to another world, tells that story, and it is now available as both an ebook and an audiobook, both with a foreword by Valerie Anders and a new introduction by Robert Zimmerman.
The print edition can be purchased at Amazon or from any other book seller. If you want an autographed copy the price is $60 for the hardback and $45 for the paperback, plus $8 shipping for each. Go here for purchasing details. The ebook is available everywhere for $5.99 (before discount) at amazon, or direct from my ebook publisher, ebookit. If you buy it from ebookit you don't support the big tech companies and the author gets a bigger cut much sooner.
The audiobook is also available at all these vendors, and is also free with a 30-day trial membership to Audible.
"Not simply about one mission, [Genesis] is also the history of America's quest for the moon... Zimmerman has done a masterful job of tying disparate events together into a solid account of one of America's greatest human triumphs."--San Antonio Express-News
The Alpha first stage, prior to September explosion
Firefly yesterday announced it has completed its investigation into the explosion during a static fire test in September that destroyed the first stage of the Alpha rocket during final preparations prior to launch.
Following a thorough review of the Alpha Flight 7 first stage ground test on September 29, Firefly identified a process error during stage one integration that resulted in a minute hydrocarbon contamination, which then led to a combustion event in one of the engines during the ground test. The test stand structure remained intact and no other facilities were impacted.
…Firefly immediately took action and implemented corrective actions, which included increasing inspection requirements for the fluid systems, optimizing the first stage sensors, and incorporating additional automated aborts. Firefly also implemented key process improvements following a daylong quality stand down where the production, integration, and test teams conducted exercises to review and optimize existing procedures. As part of Firefly’s effort to improve reliability and quality, the team will continue to hold regular exercises for sustained process enhancements.
The company also said the problem was not a design issue with the rocket.
It appears from the company’s press release that the contamination occurred because of a work force quality control issue, that required a major daylong review by all their employees to make sure their operations in building the stage would be more rigorous going forward.
The plan now is to pull another first stage from the company’s production line and stack that with the original upper stage. The target date for launch is late this year or early next year, “depending on range availability.”
Firefly had hoped to do five launches in 2025. At this moment it has only attempted one, in April, which failed. That investigation took until mid-September to complete. The next launch attempt was then delayed by the first stage explosion.
I imagine the company very much wants to get at least one launch off this year. I also imagine it is aggressively reviewing its rocket work force due to these issues.
On Christmas Eve 1968 three Americans became the first humans to visit another world. What they did to celebrate was unexpected and profound, and will be remembered throughout all human history. Genesis: the Story of Apollo 8, Robert Zimmerman's classic history of humanity's first journey to another world, tells that story, and it is now available as both an ebook and an audiobook, both with a foreword by Valerie Anders and a new introduction by Robert Zimmerman.
The print edition can be purchased at Amazon or from any other book seller. If you want an autographed copy the price is $60 for the hardback and $45 for the paperback, plus $8 shipping for each. Go here for purchasing details. The ebook is available everywhere for $5.99 (before discount) at amazon, or direct from my ebook publisher, ebookit. If you buy it from ebookit you don't support the big tech companies and the author gets a bigger cut much sooner.
The audiobook is also available at all these vendors, and is also free with a 30-day trial membership to Audible.
"Not simply about one mission, [Genesis] is also the history of America's quest for the moon... Zimmerman has done a masterful job of tying disparate events together into a solid account of one of America's greatest human triumphs."--San Antonio Express-News
Another space launch start-up climbs a bit further up the intrinsically steep learning curve of producing reliable orbital launch vehicles.