The competition heats up: SpaceX today successfully launched from Florida a Dragon capsule into orbit while also landing the first stage of its Falcon 9 rocket.
This launch initiates use of the company’s new launchpad at Cape Canaveral, as well as their effort over the coming months to hold launches every two weeks or so.
This all reeks of politics: A new Government Accountability Office (GAO) report released yesterday says that NASA it should not permit Boeing and SpaceX to fly humans on their capsules and rockets until they fix certain issues and test both repeatedly on unmanned flights before the first manned flights to ISS.
This GAO report was mandated by Congress, and it requires NASA to certify that both Boeing and SpaceX have met NASA’s requirements before allowing those first manned flights. While the technical issues outlined in the report — to which NASA concurs — might be of concern, my overall impression in reading the report, combined with yesterday’s announcement by NASA that they are seriously considering flying humans on SLS’s first test flight, is that this process is actually designed to put obstacles in front of Boeing and SpaceX so as to slow their progress and allow SLS to launch first with humans aboard.
For example, the report lists three main problems with the commercial manned effort. First there is the Russian engine on the Atlas 5. From the report itself [pdf]:
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Because of threatening weather SpaceX’s Saturday launch of Falcon 9 and the Dragon capsule might be delayed until Sunday.
SpaceX on Sunday successfully completed the launch dress rehearsal countdown and static fire test for its next Falcon 9 launch, which will loft a Dragon capsule to ISS and is set now for February 18.
The article at the link as well as a lot of other news organizations are making a big deal about the fact that this launch is taking place at the LC-39A launchpad, used during the Apollo program as well as by the shuttle. While the historic background is interesting, of more significance to me is that this test brings SpaceX closer to having two operational pads in Florida, one of which (LC-39A) is configured for Falcon Heavy launches.
SpaceX has scheduled its next launch, and first from Florida since the September 1 launchpad explosion, for February 18.
This will also be the company’s first launch from the former Apollo and shuttle launchpad that it now leases.
A forthcoming congressional report, reported by the Wall Street Journal, reveals that NASA is concerned about cracks that occur in the turbopumps of SpaceX’s Merlin engines.
The newspaper says the report has found a “pattern of problems” with the turbine blades within the turbopumps, which deliver rocket fuel into the combustion chamber of the Merlin rocket engine. Some of the components used in the turbopumps are prone to cracks, the government investigators say, and may require a redesign before NASA allows the Falcon 9 booster to be used for crewed flights. NASA has been briefed on the report’s findings, and the agency’s acting administrator, Robert Lightfoot, told the newspaper that he thinks “we know how to fix them.”
A spokesman for SpaceX, John Taylor, said the company already has a plan in place to fix the potential cracking issue. “We have qualified our engines to be robust to turbine wheel cracks,” Taylor said. “However, we are modifying the design to avoid them altogether. This will be part of the final design iteration on Falcon 9.” This final variant of the Falcon 9 booster, named Block 5, is being designed for optimal safety and easier return for potential reuse. According to company founder Elon Musk, it could fly by the end of this year.
Here’s the real scoop: SpaceX initially built the engines to fly once, just as every single rocket company has done in the entire history of space, excluding the space shuttle. Under these conditions, the cracks could be considered an acceptable issue, which is what they mean when they say “We have qualified our engines to be robust to turbine wheel cracks.” My guess is that they tested the engines, found that the cracks were not a significant problem for a single flight, especially because the Falcon 9 rocket uses nine Merlin engines on the first stage and thus has some redundancy should one fail. And based on SpaceX’s flight record — no launch failures due to failed engines — that conclusion seems reasonable.
SpaceX is now redesigning to eliminate the cracks, however, because such cracks are not acceptable for engines that will fly multiple times on reused first stages.
Thus, this story, as leaked, appears to me to be a hit job by powers in Congress who dislike the competition that SpaceX poses to big government rockets like SLS. SLS will use salvaged shuttle engines, designed initially for many reuses, and thus are superior in this manner to SpaceX’s Merlin engines. The shuttle engines however were also built by the government, which didn’t care very much about the cost of development, or making any profits. The comparison thus is somewhat bogus. Moreover, I suspect these cracks were only discovered after SpaceX successfully landed and recovered some first stages. To put them on trial in the press now for doing good engineering research and redevelopment seems somewhat inappropriate.
The report itself has not yet been released, though it does also note lingering issues with the parachutes being developed for Boeing’s Starliner capsule.
Overall, both companies are struggling to start their operational flights by 2019. For Congress or NASA to try to put more roadblocks up in that development seems most counterproductive.
The competition heats up: SpaceX has won a new launch contract, this time by launching both Iridium’s five satellites as well as the NASA/German Gravity Recovery and Climate Experiment Follow-On (GRACE-FO) mission.
Both NASA and Iridium will save money by sharing the ride, while SpaceX gets more business.
The competition heats up: SpaceX on Tuesday revealed that last week it has completed the standard static fire testing of the recovered Falcon 9 first stage that it plans to relaunch in March.
A March launch would mean an 11-month turnaround, which is far from optimal, but understandable for the first time. SpaceX’s founder and chief executive, Elon Musk, has acknowledged the company must do better in the future if resuable flight is to become economically viable. He says the next—and likely final—iteration of the Falcon 9 rocket will be optimized for reuse. “Block 5 is the final upgrade of the Falcon architecture,” he tweeted earlier this year. “Significantly improves performance & ease of reusability. Flies end of year.”
It now seems likely that SpaceX will fly the landed boosters it currently has, at most once or twice, before retiring them, instead of multiple times. Although the company hasn’t elaborated on the problems with the engines, booster structure, or composite materials that have shown wear and tear after their orbital launches and returns, Musk is confident that changes to the Block 5 version of the rocket will solve the problem. “I think the F9 boosters could be used almost indefinitely, so long as there is scheduled maintenance and careful inspections,” he has said.
In other words, SpaceX has had — for the first time in history — the opportunity to inspect a number of used first stage rockets, and that precious knowledge is making it possible for them to upgrade the stage design to make future stages more hardy. In fact, those future stages won’t be stages, but reusable vessels that SpaceX could even name if it wished.
The competition heats up: SpaceX has requested a doubling of its leased space the port of Los Angeles in order to facilitate the return of first stages launched from Vandenberg.
The Board of Harbor Commissioners will vote at its Thursday morning meeting on a deal to enlarge Space Exploration Technologies Corp.’s footprint at San Pedro’s outer harbor. The company hopes to lease 4.6 acres of land and water area along Berths 51 to 53 for $23,735 a month, plus insurance and any incidental costs.
In addition to extra space, the lease agreement allows the company to have berthing rights, install a chain-link fence around the property, build a concrete rocket-support pedestal, and add an office trailer, guard shack and portable restrooms, according to a staff report prepared for the commission.
According to the article, the increased space is needed because of the company’s plans to launch every two weeks from its pads at Kennedy and Vandenberg.
An evening pause: I’m not sure if his concept for a different way to interact with the computer is really the best way to do it, but his willingness to try something new makes it all worthwhile. There will — and have been — payoffs.
Hat tip Edward Thelen.
Because the launchpad at Kennedy is not quite ready for the planned February 3 launch of a commercial satellite, SpaceX has rearranged its launch manifest to switch that launch with the next Dragon mission to ISS, essentially delaying their next launch by two weeks.
With [launchpad] 39A still not ready to debut in its new role with SpaceX, the first mission set to launch from this pad – the Falcon 9 launch with EchoStar 23 – was pushed to the right a number of times. Although 39A is very close to being ready to conduct launches, EchoStar 23’s launch date was deemed to be too close to the mid-February target for the CRS-10 Dragon mission.
SpaceX and NASA discussed the situation on Friday night, before deciding it would be prudent to place EchoStar 23’s launch after CRS-10, allowing engineers to finalize modification and checkout work on the famous pad and simultaneously avoid a potential delay to the important Dragon mission to the Station.
The real problem here is that SpaceX had planned to have two working launchpads by this time, but doesn’t because their first pad was damaged in the September 1 Falcon 9 launchpad explosion. The consequences is that, for at least the next month, they will not be able to set a pace of a launch every two weeks.
The competition heats up: Even as SpaceX moves forward on an intense launch schedule, with launches planned for January 26 and February 8, it has begun preparations for a late February commercial launch that will be the first to reuse a first stage.
The first stage assigned to SES 10’s launch first flew April 8, 2016, with a Dragon supply ship on a logistics launch to the International Space Station. After detaching from the Falcon 9’s second stage, which continued into orbit, the 15-story first stage booster descended to a vertical landing on SpaceX’s offshore platform a few minutes after liftoff, making the first time the company recovered a rocket intact at sea.
The landing on SpaceX’s barge, or drone ship, last April came four months after the first-ever touchdown of a Falcon 9 first stage on land at Cape Canaveral. That vehicle is now on display outside SpaceX’s headquarters in Hawthorne, California.
This pace is calling for a launch every two weeks. It will spectacular if SpaceX can keep that up, but such a pace is not really unprecedented. The Soviets at their height managed it at times quite successfully.
