Did SpaceX’s Endeavour capsule have issues with its heat shield during its most recent return to Earth?

According to a May 23rd Space Explored article based on anonymous sources, the heat shield on SpaceX’s Endeavour capsule experienced “dangerously excessive wear upon reentry” because of a propellant leak.

Hypergolic propellant made its way into the Crew Dragon Endeavour’s heat shield, according to sources at SpaceX and NASA who spoke with Space Explored. This hypergolic propellant is used by the Crew Dragon in its Draco engines – hypergolic means that the two parts spontaneously combust upon contact. It is believed that this hypergolic propellant impacted the integrity of the heatshield, causing dangerously excessive wear upon reentry.

NASA however has now bluntly denied these claims:

“The data associated with Dragon’s recent crew reentries was normal — the system performed as designed without dispute. There has not been a hypergol leak during the return of a crewed Dragon mission nor any contamination with the heat shield causing excessive wear,” the NASA statement reads, in part.

“SpaceX and NASA perform a full engineering review of the heat shield’s thermal protection system following each return, including prior to the launch of the Crew-4 mission currently at the International Space Station,” the NASA statement continues. “The heat shield composite structure (structure below the tile) was re-flown per normal planning and refurbishment processes. The thermal protection system on the primary heat shield for Crew-4 was new, as it has been for all human spaceflight missions.”

Such a flat out denial by NASA strongly suggests that the anonymous sources relied on by Space Explored are not reliable, and got their facts wrong. While NASA will often try to hide or spin any issues to make them seem less worrisome, it has almost never denied the existence of a serious problem, when it was revealed that such a problem had occurred.

I know to say this sounds paranoid, but this story also suggests this claim might be part of the growing effort within the federal bureaucracy and the press to attack SpaceX, because of its new irrational hostility to Elon Musk because he supports achievement and free speech.

At the same time, SpaceX has recently had to discard and replace a Dragon heat shield planned for a future mission because of discovered “manufacturing defect” during normal preflight testing. This confirmed story, combined with the unconfirmed and questionable story above, suggests SpaceX needs to take a closer look at the Dragon heat shield design.

Endeavour splashes down successfully

UPDATE: Endeavour has successfully splashed down, and crews are approaching to recover the capsule.

This by the way completes Endeavour’s third manned flight into space.

Original post:
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The SpaceX capsule Endeavour, carrying Axiom’s first commercial passengers, undocked with ISS last night and is scheduled to splashdown off the coast of Florida shortly.

I have embedded the live stream below, scheduled to begin shortly.
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Return of Axiom mission delayed again because of weather

Because of marginal winds at the splashdown points, SpaceX, Axiom, and NASA agreed today to delay the return of Axiom’s first private mission to ISS one more day.

The Axiom Mission 1 (Ax-1) crew is now targeting to undock from the International Space Station 8:55 p.m. EDT Sunday, April 23.

Weather permitting, the Ax-1 crew is targeted to close the hatch at about 6:45 p.m. Sunday, April 24, to begin the journey home in SpaceX Dragon Endeavour with splashdown off the coast of Florida approximately 1:00 p.m. Monday, April 25.

This delay will also delay the launch of NASA’s next crew to ISS on SpaceX’s new Dragon capsule, Freedom, now scheduled for launch no earlier than April 27th.

New schedule announced for landing of AX-1 crew and launch of NASA crew

Because of poor weather at the splashdown points on Earth, SpaceX and NASA have worked out a new schedule for both the landing of Axiom’s first passenger flight to ISS as well as NASA’s next launch of astronauts.

The integrated NASA, Axiom Space, and SpaceX teams have agreed on a plan for the Axiom Mission 1 (Ax-1) crew to undock from the International Space Station at 8:35 p.m. EDT Saturday, April 23, for a splashdown off the coast of Florida about 1:46 p.m. Sunday, April 24. The decision was made based on the best weather for splashdown of the first private astronaut mission to visit the International Space Station and the return trajectory required to bring the crew and the SpaceX Dragon Endeavour spacecraft back to Earth safely.

…The departure of Dragon Endeavour from the space station will clear the docking port for the arrival of Dragon Freedom and NASA’s SpaceX Crew-4 astronauts. The earliest potential launch opportunity for the Crew-4 mission is 4:15 a.m. Tuesday, April 26, with additional opportunities Wednesday, April 27, and Thursday, April 28. These launch opportunities are undergoing a more detailed program review to ensure they align with integrated operational timelines. The teams want to provide a two-day gap after Ax-1 return for data reviews from splashdown and to prepare for the Crew-4 launch, including the staging of recovery assets.

If the landing occurs on April 23rd as now planned, the Axiom passengers will have spent fifteen days in space, about four more than originally planned.

Axiom again cancels return of manned mission due to weather

Capitalism in space: Because of continuing poor weather on Earth, SpaceX & Axiom once again canceled the planned return of manned mission yesterday.

At the moment there is no word on when SpaceX’s Endeavour capsule will undock and bring its passengers home. Since a NASA crew is preparing for launch on Saturday, April 23rd, we should expect that return to occur beforehand.

This article from Israel about the delay, which also focuses on the flight of Israeli businessman Eytan Stibbe, had this interesting tidbit:

Businessmen Stibbe, American Larry Connor of Ohio, and Canadian Mark Pathy have paid $55 million apiece for the rocket ride. The visitors’ tickets include access to all but the Russian portion of the space station. [emphasis mine]

When the Russians launched Dennis Tito and other tourists in 2000s, I am unsure if those tourists were allowed in the American portion of the station. My guess would be yes, but that would be a guess, and very easily wrong. During the two tourist flights to ISS in October and December it is also unclear if those passengers had access to the American half. Considering the competition for tourist flights that now exists, I would suspect no.

Return of first Axiom commercial crew from ISS delayed

Capitalism in space: Because of iffy weather at their planned splashdown point, SpaceX and Axiom have delayed the return of Axiom’s first commercial crew at ISS so that they will splashdown tomorrow.

Weather permitting, the four-member private astronaut crew now is targeted to undock at about 10 p.m. Tuesday, April 19, to begin the journey home with splashdown off the coast of Florida no earlier than approximately 3:24 p.m. EDT Wednesday, April 20.

If weather remains an issue, the return to Earth of Endeavour could be delayed further.

SpaceX successfully launches Axiom’s first commercial flight to ISS

Capitalism in space: SpaceX today successfully launched the first commercial mission to ISS by the private company Axiom, carrying three passengers and one Axiom astronaut as commander.

The replay of the live stream of the launch is embedded below.

The first stage, which landed successfully on the drone ship in the Atlantic, completed its fifth flight. The capsule Endeavour was making its third flight. This is also the second private manned mission launched by SpaceX.

Docking with ISS is scheduled for early tomorrow morning.

All in all, it was a perfect launch, on time and as planned. This has become so routine for SpaceX that we tend to take it for granted. We shouldn’t. Launching people into space remains one of the hardest things humans do, and will likely always be so.

The leaders in the 2022 launch race:

13 SpaceX
9 China
5 Russia
2 ULA
2 Rocket Lab

The U.S. now leads China 20 to 9 in the national rankings.
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