Tag: Boeing

Starliner return delayed again to June 26th

10:23 am

In a press briefing today, Boeing and NASA announced that they have decided to delay the return of Boeing’s Starliner capsule, carrying two astronauts, another four days to June 26, 2024. The landing would take place just before dawn, landing at White Sands in New Mexico.

The decision to delay is related to the results from the hot fire tests of the aft thrusters of Starliner on June 15, 2024. Engineers want to review the data, which included finding that one of the eight thrusters is producing unacceptable results and will not be used for the rest of the flight. The other seven thrusters however produced acceptable results, “good thrust” as noted by one official.

The extra time to review the data is also because these thrusters are on the service module, which will not return to Earth. They want to make sure they understand the issues entirely. The longer time docked to ISS is also giving them better data for future longer missions.

As for the helium leaks, the level of leaking appears to be dropping, and in fact dropped after the hot fire burns, and “appears to be somehow related to the thrusters.” Either way, the safety margins remain sufficient so that the return is not threatened in any way by these leaks.

The valve issue also seems under control, with all the valves now working as expected.

Overvall, engineers have decided they have a safe vehicle that can not only be used to return to Earth as scheduled, they are confident that they could also use Starliner as a lifeboat in a sudden emergency.

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New evidence suggests some titanium on Boeing and Airbus planes might be fake

12:36 pm

According to information provided to the FAA from Boeing, the documentation from a subcontractor for some of the titanium used on some Boeing and Airbus planes might be faked, suggesting that the titanium is fake as well.

Boeing discovered this possibility when one of its suppliers discovered holes in some metal pieces due to corrosion.

Apparently, Italian parts supplier Titanium International Group found small holes in titanium in December 2023, and also raised suspicions about the authenticity of documentation. It notified Spirit AeroSystems of the issue, which in turn informed Airbus and Boeing in January 2024. According to three anonymous sources close to the matter, affected planes include those built between 2019 and 2023 and involve the Boeing 737 MAX, 787 Dreamliner and Airbus A220 programs.

…The problem has been traced back to a Chinese supplier that sold titanium to Turkish company Turkish Aerospace Industries in 2019. Documentation from this Chinese supplier claimed that the titanium had been sourced from another Chinese firm, Baoji Titanium Industry – however, Baoji Titanium has confirmed that it did not provide this batch of titanium “and has no business dealing with this company.” [emphasis in original]

In other words, no one has any idea where that first Chinese supplier got the titanium, because its documentation was false.

Both Airbus and Boeing have done numerous tests and found no problems, though both have said they will remove any suspect parts. Spirit meanwhile has removed all the suspect parts, even though tests suggested the parts were “of sufficient quality for the aerospace industry.”

The real story here is not that these parts are unsafe (they apparently are not). The real story is the dependence by these airplane companies on so many subcontractors, some of which are subcontractors of subcontractors of subcontractors and also come from a hostile power. It leaves them all very vulnerable to others’ mistakes or malfeasance. During the Cold War it would have been inconceivable to rely on Soviet-built parts. Yet, today American airlines routine rely on Chinese companies when the Chinese government has made it clear it sees us as an enemy to be defeated.

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Starliner’s return delayed again

8:44 am

NASA today announced that the return of Starliner from ISS, carrying two astronauts, has been delayed again, from June 18th to June 22nd.

It appears engineers want to perform more tests of the the spacecraft’s attitude thrusters before undocking. The failure of some thrusters during docking on June 6th has raised some concerns.

NASA and Boeing teams also prepared plans for Starliner to fire seven of its eight aft-facing thrusters while docked to the station to evaluate thruster performance for the remainder of the mission. Known as a “hot fire test,” the process will see two bursts of the thrusters, totaling about a second, as part of a pathfinder process to evaluate how the spacecraft will perform during future operational missions after being docked to the space station for six months. [emphasis mine]

The highlighted words are kind of a lie. While there is no doubt this test will tell engineers a lot about future operations, such a test, while attached to ISS, would never have been approved had the thrusters all worked as planned during docking. The real reason for this static fire test is to make sure the thrusters will work once undocked.

If they don’t work, there could be a safety issue putting the astronauts in Starliner for return to Earth.

NASA plans a press briefing on June 18th at noon (Eastern) to outline in better detail the situation.

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Starliner at ISS: One thruster shut down, another helium leak found, and a new valve issue

9:45 am

According to an update from NASA yesterday, engineers are evaluating three different on-going technical issues with Boeing’s Starliner capsule, presently docked at ISS.

First, of the 28 attitude thrusters on the capsule’s service module, one remains what NASA calls “deselected”, which means it is presently shut down and not in the loop during operations.

Ground teams plan to fire all 28 RCS thrusters after undocking to collect additional data signatures on the service module thrusters before the hardware is expended.

Since the service module is ejected and burns up in the atmosphere, they want to test each thruster beforehand, probably one-by-one to gather as much data as possible. They have to do this after undocking because testing the thrusters while attached to ISS is too risky.

Second, it appears engineers have detected a fifth small helium leak.
» Read more

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Starliner’s stay at ISS extended several days

9:10 am

NASA revealed yesterday that it has extended the time that Boeing’s Starliner capsule will remained docked at ISS several days, with undocking now set for June 18, 2024.

New station visitors Butch Wilmore and Suni Williams, both veteran NASA astronauts, learned on Sunday they will orbit Earth until June 18 before returning home aboard Boeing’s Starliner spacecraft. The extra days in space will allow teams more time to checkout Starliner’s systems and free up the Expedition crew’s schedule for more spacewalk preparations.

I also suspect that Boeing engineers wanted more time to analyze the data on Starliner’s attitude thrusters and why several failed to work on the flight up to the station. Once the spacecraft undocks with Wilmore and Williams, it will be esssential for those thrusters to work reliably to get both home safely. The capsule can return home even with some of the spacecraft’s 28 attitude thrusters non-functioning, but if a failure occurs at an unexpected moment the results could still be bad.

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Boeing’s Starliner successfully docks with ISS

10:57 am

Despite several minor helium leaks and the failure of 6 of its 28 small attitude thrusters (four of which were reactivated during an improvised hot fire test during rendezvous operations), Boeing’s Starliner has successfully docked with ISS today.

Though now safely arrived at ISS, the hatch has not yet opened. The spacecraft carries NASA astronauts Butch Wilmore and Suni Williams, and will now spend about a week at the space station checking out its systems before undocking and returning to Earth.

All told, this docking is a success, though the various thruster issues are a concern that must be addressed by Boeing, especially because there were thruster issues as well during the previous unmanned demo flight.

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ULA’s Atlas-5 launches Boeing’s Starliner capsule on its first manned mission

9:17 am

After many delays and scrubs involving both the rocket and the capsule, ULA’s Atlas-5 rocket today successfully launched Boeing’s Starliner capsule on its first manned mission, carrying NASA astronauts Butch Wilmore and Suni Williams.

I have embedded the live stream below, cued to just before liftoff. The spacecraft will dock with ISS tomorrow, where Wilmore and Williams will spend a week checking out the capsule’s operations before undocking and returning to Earth.

As this was only the third launch this year for ULA, the leader board for the 2024 launch race doesn’t change:

59 SpaceX
26 China
8 Russia
7 Rocket Lab

American private enterprise now leads the world combined in successful launches, 69 to 40, while SpaceX by itself leads the entire world, including other American companies, 59 to 50.

» Read more

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NASA confirms June 5th as new launch date for Starliner

8:33 am

NASA yesterday evening confirmed that the agency, ULA, and Boeing are now targeting June 5, 2024 at 10:52 am (Eastern) for the launch of the first manned launch of Boeing’s Starliner capsule carrying two astronauts to ISS for a two week checkout mission.

Technicians and engineers with ULA (United Launch Alliance) worked overnight and on Sunday to assess the ground support equipment at the launch pad that encountered issues during the countdown and scrubbed the June 1 launch attempt. The ULA team identified an issue with a single ground power supply within one of the three redundant chassis that provides power to a subset of computer cards controlling various system functions, including the card responsible for the stable replenishment topping valves for the Centaur upper stage. All three of these chassis are required to enter the terminal phase of the launch countdown to ensure crew safety.

On Sunday, the chassis containing the faulty ground power unit was removed, visually inspected, and replaced with a spare chassis. No signs of physical damage were observed. A full failure analysis of the power unit will be performed to better understand root cause. Meanwhile, ULA has completed functional checkouts of the new chassis and the cards, and all hardware is performing normally.

These kinds of technical issues happen too often on ULA launches. Company engineers always fix them, but it never appears they fix them permanently. Too often on launches they pop up again, causing more scrubs.

The goal should be to fix them so they never pop up again, and your launches can begin to launch reliably, on time. And we know it can be done, because SpaceX has done it.

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Boeing Starliner launch scrubbed at T-3:50

10:10 am

UPDATE: The launch is now scheduled for June 5, 2024 at 10:52 am (Eastern).

For reasons that appeared related to the ground system’s of ULA’s Atlas-5 rocket, the first manned launch of Boeing’s Starliner’s capsule was scrubbed today at T-3:50.

It appears they want to try again tomorrow at 12:03 pm (Eastern), assuming ULA can figure out what happened.

The repeated scrubs and delays that have so far prevented this launch are beginning to remind my of my childhood watching the early NASA launch attempts during the Mercury program. Then, they hadn’t done this before, and were being very careful about everything.

Now, it seems that NASA, ULA, and Boeing are acting the same way, and that is probably because they are very nervous about Starliner and don’t want anything to go wrong.

I had intended to embed the live stream, but slept late (it IS the weekend, y’know). Sorry.

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Watching the first manned launch of Boeing’s Starliner capsule

9:31 am

NASA has now announced the broadcast schedule for tomorrow’s 12:35 pm (Eastern) launch of Boeing’s Starliner capsule on its first manned mission to ISS.

NASA will provide live coverage of prelaunch and launch activities for the agency’s Boeing Crew Flight Test, which will carry NASA astronauts Butch Wilmore and Suni Williams to and from the International Space Station.

Launch of the ULA (United Launch Alliance) Atlas V rocket and Boeing Starliner spacecraft is targeted for 12:25 p.m. EDT Saturday, June 1, from Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida. Starliner will dock to the forward-facing port of the station’s Harmony module at approximately 1:50 p.m., Sunday, June 2.

The live stream will begin on NASA TV at 8:15 am (Eastern). I will embed that live stream here tomorrow. As this start time is more than four hours before launch, expect there to be endless NASA propaganda for most of that time. My advice is to tune in at around noon.

Let us all pray that all goes well on this flight. Boeing’s recent track record has generally be horrible. We can only hope its engineers have gotten all of the kinks out of this capsule.

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NASA/Boeing/ULA confirm new June 1st launch date for Starliner

9:36 am

In a press briefing this morning officials from NASA, Boeing, and ULA confirmed the new June 1, 12:25 pm (Eastern) launch date for the first manned flight of Boeing’s Starliner manned capsule.

The officials provided a more detailed explanation of the helium leak in a valve that effects the capsule’s service module attitude thruster system, noting that it is not a design flaw but some specific issue in this particular valve. Because of this, they are confident the system can function safely even with the leak, which is relatively small.

However, the officials also noted that during their reviews in the past two weeks they discovered a new software issue in the spacecraft’s de-orbit engines that — under very unusual and unlikely circumstances — could actually cause those engines to fail to operate. They have figured out a work-around, whereby they fire the engines at a lower thrust in two stages rather than once.

Should the launch on June 1st be scrubbed for weather, they have back up dates on the next few days, though by June 4th ULA might have to swap out batteries on its Atlas-5 rocket that will require a longer stand down of several additional days.

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Boeing/NASA now targeting a June 1, 2024 launch of Starliner

9:28 am

In a brief update posted today by NASA, the agency announced that Boeing, NASA, and ULA have a new 12:25 pm (Eastern) June 1, 2024 launch date for the first manned flight of Boeing’s Starliner capsule.

The announcement was incredibly obscure about what the issues are that have caused this additional week delay:

Work continues to assess Starliner performance and redundancy following the discovery of a small helium leak in the spacecraft’s service module. As part of this work, and unrelated to the current leak which remains stable, teams are in the process of completing a follow-on propulsion system assessment to understand potential helium system impacts on some Starliner return scenarios. NASA also will conduct a Delta-Agency Flight Test Readiness Review to discuss the work that was performed since the last CFT launch attempt on May 6, and to evaluate issue closure and flight rationale ahead of the next attempt, as part of NASA’s process for assessing readiness. The date of the upcoming Flight Test Readiness Review is under consideration and will be announced once selected.

It appears that engineers are worried the leak — which is linked to one of the attitude thrusters in the capsule’s service module — might impact the ability of Starliner to return to Earth safely. It also appears there is concern about the spacecraft sitting on the launchpad for more than a month, and an evaluation is on-going on whether this might be an issue as well.

I am guessing however. A more detailed explanation might be forth-coming after press update scheduled for 11 am (Eastern) tomorrow.

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Starliner manned launch delayed again; no new launch announced

9:33 am

In a very terse statement that apparently was only sent out by email to some sources, NASA and Boeing announced last night that the May 25, 2024 launch of the first manned Starliner mission on ULA’s Atlas-5 rocket had been postponed, with no new launch date set.

NASA, Boeing, and ULA are foregoing the Saturday, May 25 launch attempt for NASA’s Boeing Crew Flight Test. The team has been in meetings for two consecutive days, assessing flight rationale, system performance, and redundancy. There is still forward work in these areas, and the next possible launch opportunity is still being discussed.

NASA will share more details once we have a clearer path forward,

The first launch scrub prior to the first launch date of May 6th was due to a valve issue on the Atlas-5 rocket. ULA quickly replaced that valve and the launch was rescheduled for May 17th. Then Boeing engineers detected a helium leak related to one of the attitude thrusters in the capsule’s service module. The launch was first delayed until May 21st, then delayed again until May 25th. Now it is delayed indefinitely.

Whether that helium leak remains the cause of this new delay remains unknown. That no new launch date has been proposed suggests the need to bring the rocket and capsule back to the assembly building to destack it in order to fix the problem. That NASA, Boeing, and ULA are being so coy about revealing any details suggests however that some additional issue might have been uncovered.

Regardless, this new extended delay is very bad publicity for Boeing. While the comparison is somewhat unfair, it continues to make Starliner look like an American version of a Yugo, not the kind of vehicle one would nonchalantly climb into for a flight into space.

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Starliner launch delayed again, to May 25, 2024

3:36 pm

Boeing, ULA, and NASA have decided to delay the first manned flight of Boeing’s Starliner capsule another four days to 3:09 pm (Eastern) on May 25, 2024.

The additional time allows teams to further assess a small helium leak in the Boeing Starliner spacecraft’s service module traced to a flange on a single reaction control system thruster. Pressure testing performed on May 15 on the spacecraft’s helium system showed the leak in the flange is stable and would not pose a risk at that level during the flight. The testing also indicated the rest of the thruster system is sealed effectively across the entire service module. Boeing teams are working to develop operational procedures to ensure the system retains sufficient performance capability and appropriate redundancy during the flight.

It appears they simply want to give themselves extra time to review their data thoroughly, with no rush, before lighting the rocket.

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Atlas-5 launch of Starliner slips to May 21, 2024

1:25 pm

While ULA has successfully replaced the valve in the upper stage of the Atlas-5 rocket, the first manned launch of Boeing’s Starliner capsule has slipped another four days, to May 21, 2024, because a newly discovered helium leak in the capsule’s service module.

Starliner teams are working to resolve a small helium leak detected in the spacecraft’s service module traced to a flange on a single reaction control system thruster. Helium is used in spacecraft thruster systems to allow the thrusters to fire and is not combustible or toxic.

NASA and Boeing are developing spacecraft testing and operational solutions to address the issue. As a part of the testing, Boeing will bring the propulsion system up to flight pressurization just as it does prior to launch, and then allow the helium system to vent naturally to validate existing data and strengthen flight rationale.

The prevous launch scrub was entirely due to the ULA’s rocket, not anything related to Boeing. This delay however is a Boeing issue, and it only reinforces the general uneasiness everyone feels about Boeing’s quality control work.

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Launch of first manned flight of Starliner rescheduled for May 17, 2024

9:31 am

Because ULA engineers have decided they need to replace the valve that forced a launch scrub on May 8th, the first manned launch of Boeing’s Starliner capsule to ISS has now been rescheduled to May 17, 2024.

The oscillating behavior of the valve during prelaunch operations, ultimately resulted in mission teams calling a launch scrub on May 6. After the ground crews and astronauts Butch Wilmore and Suni Williams safely exited from Space Launch Complex-41, the ULA team successfully commanded the valve closed and the oscillations were temporarily dampened. The oscillations then re-occurred twice during fuel removal operations. After evaluating the valve history, data signatures from the launch attempt, and assessing the risks relative to continued use, the ULA team determined the valve exceeded its qualification and mission managers agreed to remove and replace the valve.

Replacing the valve is a somewhat routine procedure, but it will take a few days, causing the two-week delay.

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Starliner launch scrubbed due to valve issue

9:21 am

Yesterday’s Starliner launch was scrubbed before launch because ULA had detected an issue with a valve on the Atlas-5’s Centaur upper stage, causing that valve to flutter because it had not closed in the proper position.

At the press conference that followed, ULA’s CEO Tory Bruno explained that during an unmanned launch, engineers would have simply cycled the valve, which almost always works to get it to seat properly. ULA launch rules however forbids it from doing so on a manned launch, because that would be the equivalent of fueling the tank with people on board the rocket. The Atlas-5 was initially not built for manned flights, and though it has been upgraded to man-rate it, those upgrades did not permit ULA this capability, unlike SpaceX’s Falcon 9, which get fueled entirely after the crew boards Dragon.

They are reviewing the data to see if the valve will need to be replaced. If not, the launch could happen quickly. If it does, the launch will be delayed slightly longer, but not significantly. Right now ULA, NASA, and Boeing are targeting a May 10th launch.

It is worth listening to Tory Bruno’s explanation of the situation because of its clarity. I have embedded his comments below, time-stamped to when he began speaking.
» Read more

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Russia to NASA: We’ll wait a bit before putting our astronauts on Starliner

8:54 am

Even though Russia and NASA have a barter deal whereby one astronaut from each country flies free on each flight of its spacecraft, Russia it appears will forego flying any Russians on Boeing’s Starliner capsule for the immediate future.

At the May 3 briefing, though, NASA officials said it was unlikely that a Russian cosmonaut would be assigned to Starliner-1 [the first operational flight after the first manned demo flight launching today]. “We expect, on the Roscosmos side, they’re more likely to want to see a long-duration flight also, so we think they’ll want to start to fly with us on Starliner-2,” said Dana Weigel, NASA ISS program manager.

That would appear to disrupt the ongoing series of seat exchanges between NASA and Roscosmos. “We’re still working through that with our Roscosmos counterparts. It’s our desire to continue to do integrated crew,” she said, adding that NASA and Roscosmos don’t have an agreement yet in place for exchanging crews in the timeframe that will include Starliner-1.

This isn’t a surprise. Russia made the same decision with SpaceX’s Dragon manned capsule, waiting until it had flown a few times before agreeing to allow its astronauts on it. With Boeing Russia might be more hesitant, consider the problems Starliner has had in development plus the overall quality control issues known to exist at Boeing.

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NASA announces launch coverage for the first Starliner manned capsule launch on May 6, 2024

10:23 am

NASA today released the details for its public media coverage of the first manned launch at 10:34 pm (Eastern) on May 6, 2024 of Boeing’s Starliner capsule.

NASA will provide live coverage of prelaunch and launch activities for the agency’s Boeing Crew Flight Test, which will carry NASA astronauts Butch Wilmore and Suni Williams to and from the International Space Station.

Launch of the ULA (United Launch Alliance) Atlas V rocket and Boeing Starliner spacecraft is targeted for 10:34 p.m. EDT Monday, May 6, from Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida. The flight test will carry Wilmore and Williams to the space station for about a week to test the Starliner spacecraft and its subsystems before NASA certifies the transportation system for rotational missions to the orbiting laboratory for the agency’s Commercial Crew Program.

Starliner will dock to the forward-facing port of the station’s Harmony module at 12:48 a.m., Wednesday, May 8.

Though that coverage includes several prelaunch and post launch press conferences, the key coverage of the launch itself will begin at 6:30 pm (Eastern) on May 6th, about four hours before the launch itself. It will also include the capsule’s docking with ISS on May 8th.

I will embed NASA’s Youtube live stream here on Behind the Black on both dates, though as always I sugggest waiting until just before launch and docking to tune in. The four hours of streaming prior to launch is mostly going to be NASA propaganda, touting the agency and often misconstruing the facts to overstate its importance. This launch will be just like SpaceX’s Dragon launches, in that almost everything will be run by the two private companies involved, Boeing and ULA, and not NASA. NASA’s real involvement will only begin at the docking to ISS.

This first manned flight of Starliner is long past due. It was supposed to occur about four years ago, but numerous technological and management problems at Boeing forced many delays. Getting that capsule operational will finally give NASA two American companies capable of putting humans in space. It will also offer some competition to SpaceX, though this competition will be weak until Boeing can demonstrate Starliner’s reliability.

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Boeing to reduce staffing for SLS due to overall delays in Artemis

9:53 am

Boeing announced yesterday that it is going to reduce the staffing for its SLS rocket, caused by delays in other parts of the program that force it to stretch out operations.

When Boeing cites “external factors,” it is referring to the slipping timelines for NASA’s Artemis Program. In January officials with the space agency announced approximately one-year delays for both the Artemis II mission, a crewed lunar flyby, to September 2025; and Artemis III, a lunar landing, to September 2026. Neither of these schedules are set in stone, either. Further delays are possible for Artemis II, and likely for Artemis III if NASA sticks to the current mission plans.

Although the SLS rocket will be ready for the current schedule, barring a catastrophe, the other elements are in doubt. For Artemis II, NASA still has not cleared a heat shield issue with the Orion spacecraft. That must be resolved before the mission gets a green light to proceed next year. The challenges are even greater for Artemis III. For that mission NASA needs to have a lunar lander—which is being provided by SpaceX with its Starship vehicle—in addition to spacesuits provided by Axiom Space for the lunar surface. Both of these elements remain solidly in the development phase.

What Boeing is telling us indirectly is that, though NASA has not yet announced any further delays in those launch dates for Artemis-2 and Artemis-3, those dates are going to be delayed, quite possibly by one or more years.

None of this is a surprise. I have long been predicting that the first manned lunar landing in the Artemis program will not take place before 2030. In fact, that date was obvious the moment NASA announced its plan to make the Lunar Gateway space station an integral part of the program, back in 2018, when it was called LOP-G.

Now that SLS development is complete and NASA considers it “operational”, Boeing is merely reducing the staffing to maintain its assembly line, reducing it accordingly because of expected delays when additional rockets will be needed.

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First manned Starliner mission now targeting a May 6, 2024 launch

8:47 am

In order to work around scheduling issues at ISS, NASA and Boeing have now scheduled the first manned Starliner mission to launch no earlier than May 6, 2024.

Following a review of the International Space Station operations, NASA’s Boeing Crew Flight Test now is targeting no earlier than Monday, May 6, for Starliner’s first launch with astronauts to the orbital complex. The date adjustment optimizes space station schedule of activities planned toward the end of April, including a cargo spacecraft undocking and a crew spacecraft port relocation required for Starliner docking. NASA and Boeing also are performing prelaunch closeout work and completing final certification for flight.

Two astronauts will fly the capsule to ISS for a two week stay, testing its systems in order to determine if it is ready for regular operations.

This launch is years behind schedule due to numerous technical problems that have cost Boeing billions in extra costs as well as lost income. In order to convince other customers besides NASA to buy seats on Starliner will likely require the capsule to fly many times without issues. Until then, I suspect anyone wishing to do a tourist flight in space will pick SpaceX instead, because of its now proven safety and reliability record.

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Boeing’s problems are only the tip of the iceberg

1:25 pm

Most of all beware this boy.’
As noted by the Spirit of Christmas Present in Dickens’ The Christmas
Carol, ‘This boy is ignorance, this girl is want. Beware them both,
but most of all beware this boy.’

Since the beginning of this year, following the near disaster when a door of a Boeing 737-Max airline blew off during the Alaska Airlines flight, the media has been obsessed with reporting every single subsequent Boeing airplane incident as attributed to bad management and quality control at Boeing.

The problem with this shallow reporting is that it fails entirely in recognizing the real depth of the problem.

First, in most of the incidents reported, the planes involved were not recent purchases from Boeing, but had been owned by the airlines for years, sometimes decades. Thus, any maintenance issues, such as a wheel falling off after take-off or a landing gear collapsing on landing or the sudden failure of an Airbus plane’s hydraulic system, are not Boeing’s fault, but the fault of the airline the plane belongs to. In the case of these particular incidents, that airline was United, and in every case, the failure was with its maintenance department, not Boeing’s bad management and poor quality control.

A similar string of incidents has also occurred at American Airlines, involving both Boeing and Airbus airplanes. With both United and American, evidence suggests that the quality of its maintenance staff has likely declined significantly since 2020, when both companies decided to abopt Diversity, Equity, and Inclusion (DEI) hiring practices, which made skin color and sex the most important qualification in hiring, rather than talent, skill, experience, or knowledge.

It is important for readers to recognize this fact when they see new stories about a Boeing plane forced to make an emergency landing, such as the story today about a United Airlines’ Boeing 787. It apparently had a cracked windshield, requiring an unscheduled landing in Chicago. The article at the link focuses a great deal on Boeing, but the focus should instead be on United Airlines, not the airplane maker, since it is United’s responsibility to keep its fleet flightworthy. When an airline fails to do so, future customers should take note, and consider other options when they need to fly.

In other words, you shouldn’t avoid flying on a Boeing plane, you should avoid flying on airlines that maintain their airplanes badly.

Having said this, I don’t want my readers to think I am trying to let Boeing off the hook. Far from it. » Read more

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The DEI disaster now appears to be hitting American Airlines

2:54 pm

American Airlines; Clowns in charge!

The continuing and almost daily airline incidents in recent weeks, with planes repeatedly being forced to make emergency landings because of mechanical failures, has too often been blamed by the media on Boeing and the airplanes it builds, when almost all of these mechanical problems have had nothing to do with that airplane manufacturer. Once Boeing sells a plane to an airline, it becomes the airline’s responsibility to maintain it and keep it airworthy. Boeing itself might have serious management and quality control problems making its new planes suspect, but when older planes fail it is not Boeing’s fault. For example, all of the recent failures at United were clearly due to failures of United’s own maintenance staff, failures quite likely instigated by that company’s decision since 2020 to make race and gender the primary qualifications for hiring, not skill, talent, or knowledge.

We are now seeing the same phenomenon at American Airlines (AA), which since December has experienced its own string of flight emergencies:
» Read more

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Another United airplane makes an emergency landing

1:26 pm

United Airlines: Run by bigoted clowns
United Airlines: Run by bigoted clowns

As more proof that the United Airlines policies for hiring and promotion — focused solely on skin color, ethnicity, and sex more than talent, knowledge, and skills — is making flying on that airline downright dangerous, another United flight today had to make an emergency landing when immediately after take-off fluid began pouring from the plane.

Just 10 seconds after flight 830 from Sydney to San Francisco took the air, video by plane spotter New York Aviation got clear images of fluid spewing from the plane — it looks like it was coming from the rear right landing gear.

The crew of the Boeing 777-300 jet continued over the ocean for a while before turning around. Video from a passenger shows the crew dumping fuel before landing. The plane landed safely back at the airport in Sydney, with no injuries, but a lot of questions.

This was the fifth such incident of a United flight in just over a week, including four emergency landings and a failure after landing.

Though this was a Boeing jet, the fault here lies entirely with United, its pilots, and its maintenance department. Though pilots should be able to rely on their maintenance departments to keep the plane airworthy, they are also supposed to check their airplanes carefully before take-off. That neither the pilots of this plane or the maintenance staff detected anything before take-off suggests that no one is really doing their job right.

No matter. United is determined to make sure that half its employees are blacks or minorities or women, no matter how little those new hires know about maintaining an airplane. So what if planes fall from the sky and people die? United will have achieved diversity, equity, and inclusion!

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United Airlines diversity quotas finally begin paying off in disaster

11:57 am

United Airlines: Run by fascist clowns
United Airlines: Run by fascist clowns

In the past week there have been four serious airplane incidents involving United Airlines. Though most of the media focus has been aimed at Boeing — which clearly has demonstrated significant management and design issues with almost all its new products in the past few years — the real culprit of these recent failures is not Boeing. All of the following potentially deadly incidents occurred on United flights, and all suggest major problems within its maintenance and hiring departments.

  • March 4: A United Boeing 737 had to make an emergency landing shortly after take-off when a fire started in one of its engines. One news report claimed the fire was caused when some bubble wrap was pulled into the engine, an explanation that seems exceedingly unconvincing, especially because no investigation has yet been completed.
  • March 7: While taking off in San Francisco, one wheel on a United Boeing 777-200 airplane fell off, crushing several cars in an airport employee parking lot, with the plane making an emergency landing in Los Angeles. United had purchased the airplane 22 years previously, so the problem had to come from within United’s maintenance department.
  • March 8: A United Boeing 737-Max ended up on the grass while taxiing off the runway after landing when its left main landing gear collapsed. One passenger reported the incident occurred due to bad driving by the pilot, who mistakenly steered the plane onto the grass, causing the gear to collapse.
  • March 8: A United Airbus A320 had to make an emergency landing in Los Angeles when it experienced “complete hydraulic failure” in one of the airplane’s three hydraulic systems.

In 2020, shortly after George Floyd’s death, United officials made a very public commitment to instituting Diversity, Equity, and Inclusion (DEI) quotas in hiring, from maintenance to pilots. For example, it announced it would favor training and hiring pilots based on skin color and sex, regardless of qualification.
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First manned Starliner mission slips to May

8:53 am

The first manned mission of Boeing’s Starliner capsule has now been delayed another few weeks, to early May, due to scheduling conflicts at ISS.

The delay was revealed as an aside in a NASA press release detailing the schedule of press briefings related to the mission. There appears to be no technical reasons for the delay. The quiet way NASA revealed it probably just indicates the agency’s embarrassment at Boeing’s overall problems with this spacecraft that have caused a four year delay in its first manned mission.

The flight will dock with ISS, last two weeks, and carry two astronauts, Butch Wilmore and Suni Williams. Its goal is to complete the final check out of Starliner prior to the initiation of operational missions. Once done, Boeing will not only begin to fly paid flights to ISS for NASA, it will be free to offer this capsule to others, including commercial tourists. Don’t expect customers to flock to buy seats, considering the many problems both Boeing and Starliner have had. Instead, it will likely take Boeing several years of NASA missions to reassure customers the spacecraft is reliable.

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ULA begins stacking Atlas-5 rocket for launching the first manned mission of Starliner

9:26 am

ULA has begun to assemble the Atlas-5 rocket that will hopefully launch Boeing’s Starliner capsule on its first manned mission to ISS, presently targeting a late April lift-off.

The rocket’s main stage was transferred from the nearby Advanced Spaceflight Operations Center to the integration facility Wednesday, Feb. 21, where it will await integration with the rocket’s upper Centaur stage and Starliner. The spacecraft will carry NASA astronauts Suni Williams and Butch Wilmore to the orbiting laboratory for a short stay of about one to two weeks before returning to a landing site in the southwest United States.

The late April date appears to be a slight delay from previous announcements.

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Lockheed Martin & Boeing get Space Force satellite development contracts

9:43 am

The Space Force has awarded Lockheed Martin and Boeing $66 million contracts each to design their own version of a new communications satellite for the military.

Over the next 15 months, the companies will create prototype satellites showing how they would meet the Space Force’s requirements for the MUOS satellites. DoD announced the contract awards Jan. 25.

The Space Force is expected to select one of the companies in 2025 to manufacture two flight-ready narrowband satellites to modernize the existing constellation of five MUOS satellites in geosynchronous orbit. Narrowband communications use relatively small amounts of data, but are critical for military operations.

A third unnamed company also bid but was not selected. The choice of Boeing for this competition is surprising, considering its numerous management and engineering problems across a wide range of products, from airplanes to space capsules. NASA itself has been so dissatisfied with Boeing’s work that in 2020 it decided at that time “to eliminate Boeing from future award consideration.” That decision appears to still stand. As far as I can remember Boeing not won any NASA contracts since.

Moreover, Lockheed Martin built the current MUOS satellites in orbit, while Boeing does not have a big reputation in recent years building satellites.

All told, it will therefore be extremely surprising if Boeing wins this competition. I suspect the Space Force issued this contract to help keep Boeing a viable company and to give it an opportunity to get its act together. Rewarding incompetence however is rarely successful.

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Starliner launch in mid-April continues on target

10:35 am

In an update today from NASA, it appears the first manned flight of Boeing’s manned Starliner capsule remains on target for a mid-April launch on a ULA Atlas-5 rocket.

Engineers continue to analyze the data from the recent parachute drop test that appeared to prove out the redesign of the capsule’s parachutes. Also, the work to replace or mitigate the flammable tape in the capsule has been completed.

Boeing completed removal of P213 tape that may have posed a flammability risk in certain environmental conditions. Boeing removed more than 17 pounds, or roughly 4,300 feet, of the material from the Starliner crew module. For areas in which removal of the tape carried an increased risk to Starliner hardware, Boeing applied tested remediation techniques such as overwrapping the P213 tape with another non-flammable, chafe-resistant tape, and installing fire breaks on wire harnesses.

No explanation as yet has been released as to how it was even possible for Boeing to have used this tape, considering it has been common practice since the Apollo 1 fire in 1967 to avoid the use of flammable materials in spacecraft. Nor has any explanation been issued on how the weak link in the main parachute connection to the capsule was not discovered until only weeks before the manned flight, last summer.

Nonetheless, both issues appear solved. After years of delays and innumerable problems, Boeing might finally be ready to fly Starliner with passengers. It desperately needs this flight to be successful, especially considering the company’s other ongoing problems with its 737 airplane. It also will not receive the rest of its contract payments from NASA until this flight is a success, and the delays and problems have cost the company more than $1.5 billion. The contract was fixed price, so Boeing has had to pay for all the additional costs from its own pocket.

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Boeing completes Starliner parachute drop test

9:13 am

Boeing on January 9, 2023 successfully completed a parachute drop test of its Starliner capsule, testing whether the redesigned connection between the chutes and the capsule was now meeting proper safety specifications.

The drop test, which used a Starliner parachute system attached to a dart-shaped sled the same weight as a Starliner, was performed to confirm the functioning of a redesigned and strengthened soft link joint that is part of the network of lines connecting the parachutes to the spacecraft. The test also validated a change to strengthen one textile joint in the parachute, increasing overall parachute robustness. As with other capsules, Starliner relies on parachutes to land safely when it returns to Earth.

Engineers are still analyzing the results, though the parachutes worked as planned. The first manned mission of Boeing’s commercial capsule is now scheduled for April 2024, only four years late as well as four years after SpaceX accomplished the same thing. It still remains staggering that the company did not find out about that soft link joint when it was designing the capsule, instead of only months before the first manned mission last year. It is not as if the use of parachutes to land capsules is cutting edge technology.

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