Blue Origin releases results of investigation into New Shepard flight failure
Blue Origin today released by email its results of its investigation into the New Shepard flight failure that occurred in September 2022, when the launch abort system activated soon after launch and released the capsule early so that it could return safely to Earth.
[T]he MIT [investigation team] determined the direct cause of the mishap to be a structural fatigue failure of the BE-3PM engine nozzle during powered flight. The structural fatigue was caused by operational temperatures that exceeded the expected and analyzed values of the nozzle material. Testing of the BE-3PM engine began immediately following the mishap and established that the flight configuration of the nozzle operated at hotter temperatures than previous design configurations. Forensic evaluation of the recovered nozzle fragments also showed clear evidence of thermal damage and hot streaks resulting from increased operating temperatures. The fatigue location on the flight nozzle is aligned with a persistent hot streak identified during the investigation.
The MIT determined that design changes made to the engine’s boundary layer cooling system accounted for an increase in nozzle heating and explained the hot streaks present. Blue Origin is implementing corrective actions, including design changes to the combustion chamber and operating parameters, which have reduced engine nozzle bulk and hot-streak temperatures. Additional design changes to the nozzle have improved structural performance under thermal and dynamic loads.
In other words, the company had made some design changes to the engine prior to launch, and these caused the hot spots that destroyed the nozzle.
The company’s email says it is fixing this issue and plans to launch “soon”, but issued no date.
Blue Origin today released by email its results of its investigation into the New Shepard flight failure that occurred in September 2022, when the launch abort system activated soon after launch and released the capsule early so that it could return safely to Earth.
[T]he MIT [investigation team] determined the direct cause of the mishap to be a structural fatigue failure of the BE-3PM engine nozzle during powered flight. The structural fatigue was caused by operational temperatures that exceeded the expected and analyzed values of the nozzle material. Testing of the BE-3PM engine began immediately following the mishap and established that the flight configuration of the nozzle operated at hotter temperatures than previous design configurations. Forensic evaluation of the recovered nozzle fragments also showed clear evidence of thermal damage and hot streaks resulting from increased operating temperatures. The fatigue location on the flight nozzle is aligned with a persistent hot streak identified during the investigation.
The MIT determined that design changes made to the engine’s boundary layer cooling system accounted for an increase in nozzle heating and explained the hot streaks present. Blue Origin is implementing corrective actions, including design changes to the combustion chamber and operating parameters, which have reduced engine nozzle bulk and hot-streak temperatures. Additional design changes to the nozzle have improved structural performance under thermal and dynamic loads.
In other words, the company had made some design changes to the engine prior to launch, and these caused the hot spots that destroyed the nozzle.
The company’s email says it is fixing this issue and plans to launch “soon”, but issued no date.