Booster landing failure on Feb 15 Falcon 9 launch began with engine issue during lift-off

SpaceX revealed today that the failure on February 15th of the 1st stage of the Falcon 9 rocket to land successfully first appeared during liftoff.

During a NASA press conference March 1 about the upcoming Crew-2 commercial crew flight, Benji Reed, senior director for human spaceflight programs at SpaceX, said that while the booster used on that Feb. 15 launch was making its sixth flight, some components on it were “life leaders” that had flown more often than any other in the Falcon 9 fleet. That included “boots,” or covers around parts of the Merlin engines in the first stage. “This was the highest count number of flights that this particular boot design had seen,” he said.

However, one of those boots had a “little bit of a hole” that allowed hot gas to get into parts of the engine during flight, he said. “A little bit of hot gas got to where it’s not supposed to be, and it caused that engine to shut down,” he said. Reed didn’t mention at what point in the launch the engine shut down, but he suggested it took place during ascent.

…The shutdown of the engine, though, kept the first stage from landing. “When that booster came to return home, because of the problem with that particular engine, we didn’t have enough thrust to get back to where we needed to be, and didn’t land where we wanted to be,” he said.

These facts help explain why SpaceX paused all its subsequent flights. An issue during liftoff is more serious than one that occurs during the return to Earth, as it suggests a problem that could impact future launches and the ability of the rocket to deliver its payload, its primary task.

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SpaceX: No 1st stage footage on tonight’s Starlink launch

During last night’s short broadcast leading to the abort at T-1:24 seconds of a launch of another 60 Starlink satellites, the company announced that it would not show the video feed from the reused first stage booster as it returned to Earth.

[A] SpaceX engineer revealed that the company would not be broadcasting live feeds from Falcon 9 B1049’s onboard cameras during the launch. The ambiguity of the comment made it impossible to determine if SpaceX was simply choosing to not show those views or if something was wrong with the camera downlink system, while the same engineer-turned-host did go on to state that “all systems are green” moments later.

No explanation for the sudden change – possibly the first webcast in years without live views from booster cameras – was given. Starlink-17 serves as a return-to-flight mission for SpaceX after Starlink-19’s failed landing, during which the rocket’s onboard cameras streamed what appeared to be clearly unusual and possibly off-nominal behavior early on in the landing process.

The article at the link then speculates that maybe SpaceX was worried about that booster’s ability to land (it will be flying its eighth time, same as the booster that failed on the earlier flight).

I am very skeptical of that theory, especially because SpaceX has never shown a reluctance to show the public its failures. Instead, I think SpaceX has decided to do an engineering test of that booster during its return, and for propriety reasons wants to keep this from public eyes. If so, the test itself might also mean they are willing to lose this booster during that test.

During the early days of their program to reuse boosters, they sometimes had the returning 1st stage do some very stressful maneuvers, producing very spectacular light shows when launched from Vandenberg on the California coast. It could be they want to test this older booster on its eighth flight in a similar manner, in order to reassess their engineering and thus make it possible to upgrade and extend the re-usability of later boosters.

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Starship #10 completes another static fire test after quick engine swap

Starship #10 at 2nd static fire test
Screen capture from LabPadre live stream.

Capitalism in space: In what to me appears a remarkable tour de force, SpaceX today completed the second dress rehearsal countdown and static fire test of its tenth Starship prototype.

What made this a tour de force is that the previous test, only two days before, had found issues with one of the prototype’s three Raptor engines. In less than two days, SpaceX engineers were able to replace that engine and fire up the rocket again.

Compare that to the operations of Boeing and NASA in trying to do a single static fire test of SLS’s core stage. Preparations for the first test took months, and when this had an issue it is now going to take at least a month (if not more) before they can attempt a second test.

If today’s Starship static fire test came up clean with no problems, a test flight to about 30 to 40,000 feet could come as early as tomorrow.

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Starship #10 completes launch dress rehearsal & static fire test

Starship #10 at static fire test
Screen capture from LabPadre live stream.

Capitalism in space: Starship #10 today successfully completed a launch dress rehearsal and static fire test in preparation for a planned 30 to 40 thousand foot test flight, possibly as soon as February 25th.

The Starship SN10 (“Serial No. 10”) vehicle performed its first “static fire” test on Tuesday (Feb. 23), lighting up its three Raptor engines for a few seconds at 6:03 p.m. EST (2303 GMT) at SpaceX’s South Texas site, near the Gulf Coast settlement of Boca Chica Village.

Static fires, in which engines briefly ignite while a rocket stays anchored to the ground, are a common preflight checkout for SpaceX. If all went well with today’s test, SN10 remains on track to launch soon — perhaps as early as Thursday (Feb. 25) — on a 6-mile-high (10 kilometers) demonstration flight into the South Texas skies.

I personally think it would be quite ironic if this Starship flies on the same day the second SLS static fire test had been originally scheduled but postponed. The contrast between the two development programs continues to be stark and astonishing. While one program has been flying test articles repeatedly as well as doing numerous engine and tank tests, the other has had trouble getting one static fire test completed without a hitch.

UPDATE: Apparently they have decided to swap out one Raptor engine based on the results of the static fire test, and thus will not do a flight tomorrow.

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SpaceX delays all launches while it investigates failed booster landing

Capitalism in space: In order to investigate the failure of the first stage to land successfully during the last Starlink satellite launch on February 15th, SpaceX has paused all further launches, with an expected delay overall of one to two weeks before launches resume.

Analysis by Scott Manley suggests during the re-entry burn (as the 1st stage re-entered the atmosphere) one of the engines had issues, causing the booster to break-up shortly before it hit the ocean.

When SpaceX was first attempting to land its first stages, the boosters would routinely crash, and the company would not slow its launch schedule because the boosters had still functioned as expected during launch. Nor was anyone disturbed by those failures nor did anyone expect SpaceX to pause further launches.

Things are different now. We have a high expectation that a Falcon 9 engine will relight and work every time, all the way back to its landing pad. Any failure later in the flight, even if the rocket got the payload into orbit, raises questions that must be answered. Hence the delay in further launches.

Overall, this higher expectation of success is a good thing. It says that we now expect rockets to be able to land successfully. And getting this problem fixed will only increase the chances that they will do so more reliably in the future.

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Second passenger chosen for private manned SpaceX mission

Capitalism in space: Jared Isaacman, who has purchased an entire Dragon/Falcon 9 flight for the first private commercial manned mission scheduled for later this year, has picked the flight’s second passenger.

The second member of a four-person crew for what’s likely to be the first privately funded orbital space tour has been identified: She’s Hayley Arceneaux, a 29-year-old physician assistant who works at St. Jude Children’s Research Hospital in Memphis, Tenn. — and was successfully treated for bone cancer at St. Jude almost two decades ago.

Arceneaux was invited to be part of the Inspiration4 mission weeks ago by its commander and principal funder, Shift4 Payments CEO and founder Jared Isaacman — but her identity was kept secret until today.

This choice fits Isaacman’s main goal, which is to use the publicity of the flight in raise money for St. Jude’s. So far almost $10 million has been raised.

Two more passengers need to be chosen. One will be picked from a lottery of people who donate to St. Jude’s, with the second being an entrepreneur picked by a panel of judges. The deadline to enter both slots closes on February 28th.

As for the flight itself, it will spend two to four days in orbit.

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Update on Starship: Flight of prototype #10 possible this week

Link here. Lots of stuff going on, with Starship prototypes 15 through 19 being assembled and waiting n the wings. Crews have also repaved and expanded the landing pad at Boca Chica, and begun assembling the first Super Heavy prototype.

The most significant tidbit to me was this:

One section inside a production tent appears to be undergoing preparations to cover the entire windward side in [thermal patches].

This unnamed section could indicate a vehicle that will be taken to an altitude that would test its heat shield under re-entry conditions. Current [thermal] patches are mostly being tested to see how they perform during the stresses of cryogenic propellant loading and launch and landing vibrations.

It is not known yet to which prototype this section belongs to, but that it is being prepared means that SpaceX is moving relentless towards that first orbital flight.

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Texas power outages delay Starliner but not Starship

Boeing announced yesterday that due to the winter storms and power outages in Texas it has delayed the second unmanned demo flight of its Starliner manned capsule from March 25 to no earlier than April 2nd.

Meanwhile, SpaceX’s Starship operation in Boca Chica, Texas has been proceeding practically unaffected by the power outages.

At the southernmost fringes of Texas, SpaceX’s Boca Chica Starship factory hasn’t been insulated from the chaos, though a large Tesla Solar and Energy installation has almost certainly lessened the blow. Highly cognizant of Boca Chica’s shortcomings for industrial-grade power needs, SpaceX installed that solar array and Tesla-made Powerpacks almost three years ago and substantially expanded it in 2020.

As a result, despite major issues posed by freezing weather and power grid instability, SpaceX has managed to keep the lights on and continue work at its Starship factory, while also slowly but surely preparing Starship serial number 10 (SN10) for its first static fire and high-altitude launch.

The weather is clearly slowing the Starship test schedule, but at least the work seems insulated from loss of power.

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SpaceX raises another $850 million in investment capital

Capitalism in space: SpaceX last week successfully raised another $850 million in investment capital in order to fund both its Starlink and Starship projects.

The article does not detail how the company plans to use the money, though it does also indicate this was not all that was raised.

In addition to SpaceX further building a war chest for its ambitious plans, company insiders and existing investors were able to sell an additional $750 million in a secondary transaction, one of the people said.

If I understand this correctly (which I admit I might not), this means SpaceX now has an additional $1.6 billion on hand in addition to the $2 billion it has previously raised.

Even if it only raised $850 million, that gives it a war chest of almost three billion for both Starlink and Starship. With Starlink already bringing in some earnings, the company should have enough to get done what it aims to do.

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SpaceX in Starlink negotiations with the Philippines

Capitalism in space: SpaceX and a major internet company based in the Philippines have been in negotiations about offering Starlink to its citizens.

US tech billionaire Elon Musk’s Space Exploration Technologies Corp (SpaceX) is in talks to bring broadband satellite services to the Philippines through a partnership with fibre internet tycoon Dennis Anthony H Uy of Pampanga.

Representatives from SpaceX and Uy’s Converge ICT Solutions Inc met on multiple occasions to discuss a potential venture, a source with direct knowledge of the matter told Philippine Daily Inquirer.

SpaceX apparently can’t just set up business to compete with this company, probably because it has deep ties in the government that can block it. Converge probably wants a cut, along with I suspect a number of Philippine politicians.

No deal has so far been made, but Starlink would be ideal in the more rural locations of the Philippines.

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SpaceX launches sixty more Starlink satellites; plus an installation report from one customer

Capitalism in space: SpaceX tonight successfully launched another 60 Starlink satellites, using its Falcon 9 rocket.

The first stage on its sixth flight however failed to land successfully. It is amazing that we now expect these landings to succeed, proving how reliable we now expect SpaceX’s rocket to be.

The 2021 launch race:

5 SpaceX
3 China
2 Russia
1 Rocket Lab
1 Virgin Orbit

The U.S. now leads China 7 to 3 in the national rankings. Another SpaceX launch is scheduled for tomorrow, followed by a Rocket Lab launch a little more than 24 hours later.

A report from one Starlink customer on his installation experience

The sixty new Starlink satellites bring the constellation to more than 1,100 satellites, allowing SpaceX to continue expanding regions where it is offering the service. Below the fold is an update from reader Steve Golson on his experience installing his own Starlink dish and service in Maine, now running for several days. Rather than cut and past sections, I think it best to quote his email to me in its entirety, including some of the images he sent. The opinions expressed are Steve’s alone, but they are coming from a customer who appears very satisfied with the product, up to now.
» Read more

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Falcon Heavy wins contract to launch 1st two Gateway modules

NASA today awarded SpaceX a $331 million contract to launch the first two components of the Lunar Gateway space station, using its Falcon Heavy rocket.

The Gateway’s Power and Propulsion Element and Habitation and Logistics Outpost will launch in tandem no earlier than May 2024 aboard the Falcon Heavy rocket from pad 39A at NASA’s Kennedy Space Center in Florida.

The $331.8 million launch services contract, awarded by NASA’s Launch Services Program at Kennedy, includes the Falcon Heavy launch and “other mission-related costs,” the agency said in a statement. The $331 million contract value is nearly three times the price NASA is paying for a Falcon Heavy launch in July 2022 with the Psyche asteroid probe.

What is significant about this contract is what it does not mention: SLS. Gateway was originally conceived by NASA as a project that would give purpose to the SLS rocket, a rocket that Congress required NASA to build without giving it any mission. Now it appears NASA is looking to build Gateway without SLS, at least on this first launch.

I would throw this news item in the bin containing an number of recent stories, all of which signal that SLS is on increasingly thin ice.

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