Tag: engineering

South Korea pinpoints cause of October launch failure

9:39 am

The new colonial movement: South Korea’s space agency KARI has completed its investigation of the launch failure in October of its first entirely home-built Nuri rocket, revealing that the support structures for the rocket’s helium tanks were designed incorrectly, and allowed the tanks to break free during launch.

“The support structures holding helium tanks inside the third-stage oxidizer tank were not properly designed to account for a force referred to as buoyancy,” KARI said in a Dec. 29 statement. Buoyancy, the upward force exerted by a fluid that pushes an object, rises along with a rocket’s altitude, which was not accounted for, according to KARI.

The helium tanks with the faulty anchors were inside the upper stage’s oxidizer tank, which was filled with liquid oxygen needed for the rocket’s ignition. With the helium tanks coming loose, they disrupted pipelines within the oxidizer tank and led the liquid oxygen to leak, resulting in early termination of the ignition, KARI explained.

The helium is used to keep the tank pressurized as it uses up its oxygen so that oxygen will continue to flow to the engine. Thus, they sit inside the oxygen tanks, and when they came loose they damaged its internal pipes.

Though they can fix the problem, it will likely cause a delay in the second Nuri launch attempt, presently scheduled for May.

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Update on Starship/Superheavy development

9:30 am

Link here.

The article first provides a detailed review of the past year’s effort, which leads to laying out the possibilities for 2022. Key quote:

With the FAA citing its plans to issue the Final Programmatic Environmental Assessment (PEA) for the SpaceX Starship / Super Heavy project no earlier than the end of February, SpaceX can claim the review process is the schedule driver. However, [Superheavy] Booster 4 [intended for Starship’s first orbital flight] has yet to conduct a Static Fire test, likely including an eventual full 29 engine firing. Further evolutions of the Ship and Booster are yet to come online, with a plan to go to nine engines on Ship and 33 engines on the Booster, all moving to the Raptor 2 variant.

In other words, there is a lot of work that needs to be done before SpaceX can actually fly that first orbital flight of Starship/Superheavy, and that even if the FAA rubberstamped the approval of its environmental reassessment of the Boca Chica site today, SpaceX would likely not be able to launch that orbital flight for several months anyway.

The article also suggests that SpaceX has made big progress in rethinking the Raptor manufacturing process, and has aimed those changes for the production of the Raptor-2 engine, which will also be about 20% more powerful than the Raptor engines presently being installed.

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2021: The year that private enterprise took over rocketry

2:50 pm

The year that just ended, 2021, was for the field of rocketry the most successful year since the launch of Sputnik in 1957. In a year when the world was still racked by COVID panic and its oppressive restrictions on both private and public life, the global launch industry was able to rack up the most launches ever, successfully completing 134 launches and topping the previous best year, 1975, by one.

The chart below shows all successful launches by every nation in the 21st century. It also shows in the U.S. the breakdown of those launches by private companies.
» Read more

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A review of China’s space program

8:42 am

Link here. The article covers China’s achievements in ’21, then reviews the status of its rocket development program. The key quote to me however was this, describing the upcoming plans for the assembly of China’s space station:

In 2022, China is expected to launch two more crew rotations to the Tiangong station using its Shenzhou spacecraft. The first, Shenzhou 14, is expected in May, while the second one will launch in November. Both missions will launch aboard Chang Zheng [Long March] 2F/G rockets. Two more modules for the space station are also planned to launch in the course of the year.

These new modules are the laboratory cabin modules (LCMs). The first is named Wentian, meaning Quest for the Heavens, while the second is Mengtian, or Dreaming of the Heavens. Both will launch on Chang Zheng 5B rockets, with Wentian currently scheduled to lift off in May or June, with Mengtian planned to launch in August or September.

This means that — assuming China has not reworked the design of its Long March 5B rocket — a large out-of-control core stage will be crashing to Earth in the the spring and late summer.

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Iran finally admits rocket launch on December 30th was a failure

5:33 pm

One day after implying that the test launch of Iran’s Simorgh orbital rocket on December 30th was actually a suborbital flight and was a success, that same official admitted yesterday that this was not true, that the plan had been to put three satellites in orbit, and that the launch was a failure.

Ahmad Hosseini, an Iranian defense ministry spokesman, revealed that the rocket failed to put its three payloads into orbit after the rocket was unable to reach the required speed, according to the news agency.

“For a payload to enter orbit, it needs to reach speeds above 7,600 (meters per second). We reached 7,350,” he said in a documentary broadcast on state TV.

It was Hosseini who claimed the launch was a success the day earlier, implying that the low speed was because the flight was intended to be suborbital. Either he knows nothing about rocketry (very likely), or is merely a mouthpiece who was ordered to change his story when the first story was laughed out of the room (also very likely).

The article at the link focuses on France’s condemnation of the launch, claiming it was a ballistic missile.

France’s foreign ministry said the launch was in breach of UN Security Council resolutions, Reuters reported. “We call on Iran not to launch further ballistic missiles designed to be capable of carrying nuclear weapons, including space launchers,” the ministry said.

Simorgh however is not a ballistic missile. Everything I have read about it suggests it is designed to put payloads in orbit, not deliver bombs to other parts of the globe. A ballistic missile is technically a very different thing. It usually uses solid rockets which can be stored for long periods and launched at a moment’s notice. Simorgh uses hypergolic fuels which — though they can be used on ballistic missiles — are rarely used for that purpose because of their toxic nature.

At the same time, these facts about Simorgh should not make us think Iran is not a threat. If you can develop the manpower and technical know-how to built an orbital rocket, you will also have increased your ability to build missiles. Iran is without doubt working to develop both.

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The unfurling of Webb’s sun shield begins

5:18 pm

Engineers have begun the multi-day unfurling and deployment of the sun shield on the James Webb Space Telescope.

The first step is to deploy two booms on each side of the telescope that draw the shield itself outward.

The deployment of the first boom was held up several hours to give engineers time to make sure the protective covers had, in fact, rolled off to the side of the sunshade pallets as required.

“Switches that should have indicated that the cover rolled up did not trigger when they were supposed to,” NASA said in a blog post. “However, secondary and tertiary sources offered confirmation that it had.”

“The deployment of the five telescoping segments of the motor-driven mid-boom began around 1:30 p.m., and the arm extended smoothly until it reached full deployment,” NASA said.

Engineers then sent commands to deploy the second sunshade boom, which extended smoothly and locked in place at 10:13 p.m., finally giving Webb its iconic kite-like shape.

Next the shield has to be tightened in place, which will also separate and tighten in place the shield’s five layers. According to the schedule, the four layers will be tensioned today, with the fifth tomorrow.

The step-by-step deployment is outlined in detail here, and updates to the most recently completed step after it is finished.

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Wall Street financial firm condemns Astra as bad investment

10:02 am

Capitalism in space: In a blunt critique announcing its decision to short sell Astra stocks, the Wall Street financial firm Kerrisdale Capital condemned the startup rocket company as a poor investment.

Kerrisdale’s analysis focuses on two issues, Astra’s under-powered rocket and the company’s prediction that it will launch as many as 300 rockets a year by 2025.

Astra’s rocket launch projections are nonsense. No market analysis supports Astra’s planned 300+ launches by 2025. Excluding satellites from SpaceX and China from industry-wide forecasts, there is insufficient demand to support even a fraction of Astra’s aggressive forecast.

Large launch vehicles are a more efficient and cost-effective solution to deploying whole orbital planes versus piecemealing coverage through a series of small launches and will dominate the market for mega-constellations (which are widely expected to comprise the bulk of all satellites deployed over the next decade). Only scraps will remain for Astra and all the other smaller launchers—far less than Astra needs to turn a profit.

Astra is falling behind its competitors. Multiple industry executives we interviewed, who routinely secure launch services for small satellite manufacturers on a global basis, agree that Astra’s rocket dimensions and payload capacity are well below the “sweet spot” of customer needs.

The publication of this report caused an immediate 10% drop in Astra’s stock, though it then recovered somewhat.

The report has some validity, though it assumes that the market for rocket launches will remain the same as it has for decades, an assumption that is simply false. Things always change. What happened before is no guarantee it will happen that way in the future.

Moreover Astra’s strategy is to built a small rocket that is very very cheap. It hopes that low price will bring it cubesat customers who want a launch on schedule and sent to their chosen orbit, something they do not get when they are secondary payloads on larger rockets. There is a strong possibility that this strategy will work, based on the fast growth in the satellite industry in the past decade when SpaceX and Rocket Lab forced launch costs to drop from $100 to $500 million to $6 to $60 million.

Kerrisdale’s report however is a valid wake-up call, and suggests that Wall Street’s recent passion to pour money into many new startup rocket companies (estimated by some to exceed a hundred) might finally be easing.

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SpaceX raises another $337 million in investment capital

9:45 am

Capitalism in space: In an SEC filing yesterday SpaceX revealed that it has raised another $337 million in investment capital.

The company raised in 2021 a total of $1.85 billion, and over the last six years has raised close to $7 billion total. While some of that capital is being used to finance its Starlink internet constellation of satellites, most is being funneled into the development of its totally reusable heavy lift Starship/Superheavy rocket.

The eagerness of investors to put money behind SpaceX is a strong vote of confidence in the company, coming from totally independent sources.

Adding in the $2.9 billion dollar contract from NASA for building a lunar lander version of Starship, SpaceX has raised about $10 billion total for building this rocket.

Whether that will be enough of course is not yet known. Based on SpaceX’s past work it should be. That however assumes the federal government’s bureaucracy doesn’t throw a serious wrench in the process, something it right now appears to be doing by stalling the orbital test flight of Starship/Superheavy.

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1st stage of Webb sun shield deployment completed

9:29 am

The deployment of the forward and aft pallets required to support the sun shield for the James Webb Space Telescope has apparently been successfully completed.

The link takes you to the website that outlines each step in Webb’s entire 30-day deployment sequence, and is updated to show you the next required step as the process continues. Though I have yet to see any official announcement, this page now shows that both pallets have successfully unfolded and that the next step is removal of the covers that have protected the sun shield membrene during assembly and launch.

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Iran launches orbital Simorph rocket, does not reach orbit

3:09 pm

According to Iran’s state run press, it successfully launched its orbital Simorgh rocket on a test suborbital flight today, carrying three payloads to an altitude of 292 miles.

Ahmad Hosseini, an Iranian defense ministry spokesman, said the satellite-bearing rocket named Simorgh, or “Phoenix,” had launched the three cargoes at an altitude of 292 miles (470 km) and at a speed of 7,350 meters (4,5 miles) per second. “The intended research objectives of this launch were achieved,” Hosseini said, in comments broadcast on state television.

“This was done as a preliminary launch … we will have an operational launch soon,” the spokesman added, without further clarifying whether the devices had successfully entered Earth’s orbit.

In 2020 Iran completed an orbital launch using a mobile launcher, which probably used a different solid rocket instead of Simorgh.

However, since Simorgh is intended as an orbital rocket and it did did not reach orbit this time strongly suggests the rocket failed. Since the Iranian press provided images of the rocket in flight soon after launch, the failure possibly occurred at first stage separation followed by ignition of the second stage, a critical moment in a launch where failures often occur.

No matter. Whether it failed or functioned exactly as planned, this launch will provide Iranian engineers valuable information for that inevitable successful orbital flight.

As an orbital rocket designed to launch satellites, Simorgh actually poses less of a threat than that mobile launcher from 2020. Simorgh isn’t really a missile designed to launch bombs. It takes too long to fuel, and its launch site is vulnerable. The mobile launcher used in 2020, likely using solid rockets, is far more dangerous.

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The badlands on the floor of Valles Marineris

1:03 pm

The badlands on the floor of Valles Marineris
Click for full image.

Cool image time! The recent discovery that there might be a near surface reservoir of ice on the floor the canyon Valles Marineris, near the Martian equator, immediately brought this location to the forefront as a possible site for establishing colonies. The weather will be less harsh than higher latitudes, the low elevation means a thicker atmosphere, and the terrain will be more appealing than the boring flat northern lowlands.

The picture to the right, cropped and reduced to post here, illustrates however the likely difficulties of landing and living on the floor of Valles Marineris. Taken on July 26, 2021 by the high resolution camera on Mars Reconnaissance Orbiter (MRO), the photo shows just one small area of the floor of Ius Chasm, the western part of Valles Marineris and about 300 miles to the east of that water reserve.

In this one picture we can see trapped sand dunes in hollows, eroded depressions, mottled terrain resembling stucco, and innumerable cliffs and sinks and plateaus. For the first manned spacecraft to land on Mars, this is not a good first choice. Even later, when the first bases have been built, this terrain would still be forbidding for the early colonists to land in and traverse.

The overview map below shows exactly where this picture is relative to the rest of the Valles Marineris.
» Read more

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U.S. military adds Blue Origin to its point-to-point space cargo development program

9:50 am

Capitalism in space: The U.S. military on December 17th signed an agreement with Blue Origin to add it to its point-to-point space cargo development program.

The command last year signed similar agreements with SpaceX and with Exploration Architecture Corp. (XArc). Blue Origin is the third company to ink a CRADA [as these development contracts are called] for the rocket cargo program.

Under CRADAs, companies agree to share information about their products and capabilities but the government does not commit to buying anything. U.S. TRANSCOM’s analysis of industry data will inform the newly created “rocket cargo” program led by the Air Force Research Laboratory and the U.S. Space Force. The Air Force in its budget proposal for fiscal year 2022 is seeking $47.9 million to conduct studies and rocket cargo demonstrations. [emphasis mine]

I highlight the total budget of this program to show that this is a very small government program. The cash it provides these three companies is nice, but it is chicken feed when compared with the total cost of development. It certainly will not result in a faster pace at Blue Origin in developing its New Glenn rocket, which is presently two years behind schedule with further delays almost certain because its BE-4 rocket engine is not yet ready for mass production.

Whether the program itself is a good thing, or merely another example of government crony capitalism, is open to question. The practicality of using either Starship or New Glenn for cargo transport remains very unproven, especially for New Glenn, which was not designed with such a purpose in mind and cannot land its upper stage on Earth as Starship can.

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