Tag: Starliner

Boeing and Aerojet Rocketdyne fight over cause of Starliner valve problem

6:01 pm

In a Reuters story today, it was revealed that Boeing and Aerojet Rocketdyne are in a fight over the cause of Starliner valve problem, where thirteen valves failed to work and caused the scrub of a launch attempt last summer, delaying almost a year to next week.

A team of Boeing and NASA engineers is in general agreement that the cause of the stuck valves involves a chemical reaction between propellant, aluminum materials and the intrusion of moisture from Starliner’s humid Florida launch site.

Aerojet engineers and lawyers see it differently, blaming a cleaning chemical that Boeing has used in ground tests, two of the sources said.

It appears that Aerojet is attempting to put the blame on Boeing because it might be liable for the cost of redesigning the valves, as well as other costs associated with the delays since last year.

The article also reveals that the valves being used in the Starliner capsule to be launched next week have only a temporary fix for the problem, and that Boeing intends to redesign them to prevent the problem in the future.

All in all, this whole fiasco does not speak well for either Boeing or Aerojet. It remains completely inexplicable for any spacecraft to be built with this kind of valve problem, now, after six decades of launches from wet and humid Florida. The problem reeks of bad design or poor quality control procedures by both companies.

The article further confirms these quality control problems by this tidbit in its last paragraph:

In 2017, Starliner had an accident during a ground test that forced the president of a different subcontractor to have his leg medically amputated. The subcontractor sued, and Boeing subsequently settled the case.

That this accident has been kept out of the news is somewhat shocking. For it to happen at all reveals a lot about the sloppy way Boeing operates these days.

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ULA begins stacking Atlas-5 rocket that will launch Starliner on demo mission

9:19 am

Capitalism in space: ULA has begin assembling the Atlas-5 rocket it will use in May to launch Boeing’s Starliner manned capsule on its second unmanned demo mission.

The article provides a detailed description of the status of both the rocket and the capsule, including this update on the valve issues that caused the August ’21 launch of this second demo mission to be scrubbed:

Engineers believe the valve components likely corroded from the interaction of nitrogen tetroxide propellant with moisture that seeped into the thrusters on the spacecraft’s service module, then permeated a Teflon seal inside the valve itself.

Technicians removed the service module from the Starliner’s crew module in January for shipment to a test facility in New Mexico, where teams are performing tests to better understand the valve problem. The OFT-2 [in May] mission will fly with a new service module, one originally assigned to the first Starliner mission with astronauts. Teams inside Boeing’s Starliner hangar mated the crew module with the new service module March 12. Filling of the service module with propellant is expected to occur this month, before the spacecraft rolls over to ULA’s rocket integration building for stacking atop the Atlas 5.

Boeing said the Starliner team designed a new purging system to help prevent moisture from getting into the valves during the upcoming launch campaign while the spacecraft is in the factory and at ULA’s launch site.

Boeing’s engineering failures with Starliner have been expensive to the company. Not only has Boeing had to pay out of its own pocket an extra $410 million for this second demo flight, it has had to write off the cost of that first service module. Furthermore, not being operational has probably meant it has lost business to SpaceX and its Dragon capsules. For example, when Axiom first announced it was going to fly commercial tourist flights in 2018, it was expected the company would use both Dragon and Starliner capsules. That might still happen, but at least for the first few years of operations all of Axiom’s business has gone to SpaceX. NASA has also had to throw all its manned flights to SpaceX for the next few years, some of which was originally aimed at Boeing.

Should this second demo flight succeed, however, the company will finally be in a position to launch passengers on Starliner and thus make money from the capsule.

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Boeing and NASA set May 19th for second Starliner unmanned demo launch

10:21 am

NASA yesterday announced May 19th as the new launch date for Boeing’s second attempt to complete the first unmanned Starliner demo mission to ISS.

The uncrewed mission will test the end-to-end capabilities of the Starliner spacecraft and Atlas V rocket from launch to docking and return to Earth at one of five designated landing zones in the western United States. Following a successful completion of the OFT-2 mission, NASA and Boeing will determine a launch window for NASA’s Boeing Crew Flight Test (CFT), Starliner’s first flight with astronauts aboard.

The first unmanned demo flight in December 2019 failed to dock with ISS and had to be cut short due to serious software issues. The launch of the second unmanned demo flight was scrubbed mere hours before launch in August of 2021 due to serious valve issues.

Thus, Boeing’s manned capsule is more than two years behind schedule. Not only has Boeing had to pay more than $400 million for a second demo mission, the delays have caused a lot of business with NASA and with tourists to instead go to SpaceX. Hopefully, the company has finally fixed all issues and will succeed and begin manned operations later this year.

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Boeing and NASA still aiming for a May launch of unmanned Starliner test demo

7:58 pm

Capitalism in space: Boeing and NASA are still targeting a May launch of Starliner’s unmanned test demo flight to ISS, delayed since August because of a valve issue in the service module.

Though they think they have identified and fixed that sticky valve problem, they have also decided to replace the service module for the demo flight, using the module originally planned for the first manned flight that will follow.

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Boeing switches Starliner service modules for unmanned demo flight

8:57 am

According to a NASA press release today, Boeing has decided to swap Starliner service modules for the capsule’s first two missions, using the service module intended for the first manned flight on the unmanned demo flight, and assigning the service module for the unmanned demo flight — which had the valve issue — to the first manned flight.

The launch schedule for these two flights is now targeting May for the unmanned demo flight and August for the first manned Starliner demo mission.

Ongoing investigation efforts continue to validate the most probable cause to be related to oxidizer and moisture interactions. NASA and Boeing will continue the analysis and testing of the initial service module on which the issue was identified leading up to launch of the uncrewed OFT-2 mission in August 2021.

In other words, though they are claiming that they have figured out the sticky valve problem in that service module, it is also quite likely that it will not be used in August 2021. I suspect they will eventually put it aside and use another service module for the manned mission, and have only said now that they will use it on the manned mission for PR reasons. It appears they are confident the valve issue is solved for other service modules, but are not yet satisfied this troublesome service module is trustworthy.

The May-August schedule is tight, but doable, assuming the May unmanned flight goes well. If the August manned demo mission also goes well, Boeing will finally be able to begin selling seats on its Starliner capsule, though I would not be surprised if it makes no sales to anyone but NASA for the next few years. Considering its problem-filled development, private users are going to be reluctant to use this capsule until it establishes a successful track record.

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NASA buys more Dragon manned flights

9:41 am

Capitalism in space: To give it some coverage because of continuing delays in Boeing’s Starliner manned capsule, NASA announced yesterday that it has awarded SpaceX contracts for three more manned Dragon manned flights to ISS.

NASA issued a contract notification announcing its plans to issue a sole-source award to SpaceX for three missions. Those missions would be in addition to the six “post-certification missions,” or PCMs, that SpaceX won as part of its $2.6 billion Commercial Crew Transportation Capability (CCtCap) contract in 2014. The announcement did not state the price of those three new missions.

This is money that would have gone to Boeing, if it had gotten its act together and gotten Starliner flying on schedule. Instead, SpaceX is making the profits.

There has been no updates from Boeing since October on the valve issue that now stalls Starliner. While Boeing claims it is aiming for an unmanned demo flight to ISS in early ’22, this remains entirely speculative at this moment.

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Starliner delays have cost Boeing another $185 million

10:02 pm

Capitalism in space: Boeing today announced that it has had to taken another $185 million charge out of its earnings, in addition to the $410 million previously deducted, in order to cover the problems and delays in developing its Starliner manned capsule.

When Boeing took the original earnings charge, it said it did so because it committed to redo the uncrewed flight test at no expense to NASA, a point a Boeing executive reaffirmed at the Oct. 19 briefing. “There’s no additional charges that will be going to the government for this. This is something that The Boeing Company will make sure we’ve got covered as we get this vehicle prepared,” said John Vollmer, vice president and program manager for Boeing’s commercial crew program.

These costs are beginning to pile up. Boeing has got to get this capsule fixed and flying, not only to begin bringing in some income but to show the world that it can do this right.

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Sierra Space teams up with Blue Origin to build its Life space station

10:45 am

Proposed Orbital Reef space station

Capitalism in space: Sierra Space and Blue Origin today announced [pdf] that they are forming a consortium of space companies to build a space station they dub Orbital Reef. From the press release:

The Orbital Reef team of experts brings proven capabilities and new visions to provide key elements and services, including unique experience from building and operating the International Space Station:

  • Blue Origin – Utility systems, large-diameter core modules, and reusable heavy-lift New Glenn launch system.
  • Sierra Space – Large Integrated Flexible Environment (LIFE) module, node module, and runway-landing Dream Chaser spaceplane for crew and cargo transportation, capable of landing on runways worldwide.
  • Boeing – Science module, station operations, maintenance engineering, and Starliner crew spacecraft.
  • Redwire Space – Microgravity research, development, and manufacturing; payload operations and deployable structures.
  • Genesis Engineering Solutions – Single Person Spacecraft for routine operations and tourist excursions.
  • Arizona State University – Leads a global consortium of universities providing research advisory services and public outreach.

I suspect that this deal is actually telling us that Jeff Bezos is spreading some of his Blue Origin money to help finance Sierra Space’s work. The deal also appears to be an effort to generate work for Blue Origin’s not-yet-launched New Glenn rocket and Boeing’s not-yet launched Starliner capsule.

The release says nothing about target dates, but the overview [pdf] on the Orbital Reef website says they are aiming for the second half of this decade.

While the success of such a project can only increase the competition and lower the cost to orbit, thus making the settlement of space more likely, this announcement reeks of the same kind of high-minded promises that came with Blue Origin’s Blue Moon lunar lander: Big plans by the best and most established space companies, with little firm commitment by these companies to actually build anything.

Compared to the Blue Moon lunar lander project, however, this project has one very significant difference that could make it real. Orbital Reef is not being touted in order to win a government contract. It is being touted as a commercial station for private customers. Such a project will require these companies to either invest their own money, or obtain outside investment capital, to build it. To make money they can’t sit and wait for their customers to pay for it, since customers never do that (except the government). They need to first build it.

Meanwhile, the BE-4 engine is not yet flight worthy, so that Blue Origin’s New Glenn rocket remains no closer to launch, even though it is now approaching two years behind schedule.

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Boeing to take Starliner apart, remove two valves

4:57 pm

Boeing has decided to take apart the Starliner capsule intended for its second unmanned demo flight to ISS to do a close inspection of two of the troublesome valves that caused the launch in August to be scrubbed.

The current guess at what caused the valve issue involves moisture that accumulated near some of the valves’ Teflon seal. But without any clear culprit, the company now plans to ship two of the valves to a NASA center in Huntsville, Ala., for a forensic CT scan, using machines similar the ones used on humans to detect diseases.

This action now means that the next launch attempt will likely be delayed until the middle of ’22.

The delay is costing Boeing money, not NASA, as the contract is fixed price and Boeing will not get paid additional money until it meets its next milestone, which is a successful demo flight to ISS.

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Update on Boeing’s investigation into Starliner valve issue

10:10 am

NASA yesterday issued an update on Boeing’s investigation into Starliner valve issue, noting that progress is being made.

Boeing has demonstrated success in valve functionality using localized heating and electrical charging techniques. Troubleshooting on the pad, at the launch complex, and inside the Starliner production factory at Kennedy Space Center has resulted in movement of all but one of the original stuck valves. That valve has not been moved intentionally to preserve forensics for direct root cause analysis.

Most items on the fault tree have been dispositioned by the team including causes related to avionics, flight software and wiring. Boeing has identified a most probable cause related to oxidizer and moisture interactions, and although some verification work remains underway, our confidence is high enough that we are commencing corrective and preventive actions. Additional spacecraft and component testing will be conducted in the coming weeks to further explore contributing factors and necessary system remediation before flight.

…Boeing has identified several paths forward depending on the outcome of the testing to ultimately resolve the issue and prevent it from happening on future flights. These options could range from minor refurbishment of the current service module components to using another service module already in production. [emphasis mine]

The announcement also confirmed that the next launch attempt of the unmanned demo mission is now being targeted for “the first half of 2022, pending hardware readiness, the rocket manifest, and space station availability.”

The highlighted words raise a very serious question. How is it possible for “oxidizer and moisture interactions” to cause this problem now on Starliner, when the environmental conditions at Cape Canaveral for spacecraft have been understood for better than sixty years? Though this problem might have uncovered a previously undetected fundamental engineering issue related to valves, I am very skeptical. It seems more likely that some quality control issue occurred during this capsule’s assembly. That they are considering using a different Starliner capsule for the demo flight strongly confirms this, suggesting again that the valve issue is not systemic to all valves but is specifically linked to the assembly of this capsule.

If this speculation is correct, it suggests there are some some very disturbing quality control problems in Boeing’s Starliner design and assembly processes. First they missed about sixty software issues that forced the premature landing of the capsule in the first demo flight, issues that should have been fixed during design and construction. Now it appears they have discovered assembly problems with the capsule’s valves, and only did so mere hours before launch.

Boeing has got to get these issues fixed, or it is going to have a serious public relations problem garnering private customers outside NASA once Starliner begins commercial flights.

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NASA shifts Starliner crew to Dragon to get them in space

9:54 am

NASA announced yesterday that it is is changing the launch assignments of two astronauts from Boeing’s long delayed Starliner capsule to SpaceX’s Dragon capsule, thus allowing them to get into space sooner.

Astronauts Nicole Mann and Josh Cassada were supposed to be among the first human passengers on Starliner during its first crewed flights in the coming years. Now, they’ll fly together on SpaceX’s fifth crewed mission to the International Space Station, which is slated to take place in the fall of 2022.

Both had been assigned to Starliner in 2018, but the delays at Boeing have left them stranded on the ground while others are flying. Worse, it is now unclear when Starliner will launch, as Boeing has not yet resolved the serious valve issue that scrubbed the launch of Starliner’s second unmanned demo mission in August.

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Starliner unmanned demo flight likely delayed until ’22

9:20 am

Capitalism in space: The second Starliner unmanned demo flight, repeatedly delayed throughout ’21 due to scheduling and technical problems, is now likely to be delayed until next year.

Apparently, Boeing engineers have been unable to figure out why 13 of 64 valves on Starliner failed to function properly just hours before the last planned launch, causing the launch to be scrubbed.

The quality control systems at Boeing during this entire program have not shined. The capsule is now years behind schedule, and has been dogged by design and construction flaws — from software to parachutes to valves — that in the 21st century should not be problems any longer in building a manned spacecraft.

Like SpaceX and its Dragon capsule, Boeing owns Starliner and will be able to offer private citizens and companies flights on it once it is operational. These failures, however, will not be good for that future business. They make this spacecraft a far less appealing product when compared to the high quality of the engineering at SpaceX. Why would anyone risk their life on Starliner when they can buy a ticket on the apparently much more reliable Dragon?

In other words, Boeing has been doing terrible harm to its brand name with these problems. It needs to get them fixed, and fast.

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Boeing to return Starliner to factory

11:11 am

Capitalism in space: According to a Wall Street Journal story today, Boeing and NASA have decided to remove the Starliner capsule from the Atlas-5 rocket and return it to Boeing’s factory in order to do a more thorough inverstigation into the capsule’s failing valves.

This decision means that the launch of the second unmanned demo test flight of Starliner will not occur in August, and will likely be delayed several more months. NASA and Boeing just held a press conference in which they made this decision official. During that conference they said they think the moist environment at Kennedy might have caused corrosion in the valves, which caused them to stick.

I once again wonder if Boeing has any quality control systems at all. For such a serious problem — the failure of 13 valves out of 24 — to suddenly pop up just hours before launch, when they have been developing this capsule for years, and even had an extra year and a half to check the capsule out after the failures during the first unmanned demo flight in December 2019, is somewhat astonishing, and very disturbing.

Others will argue that problems like this can always appear unexpectedly in space hardware. I say hogwash. Boeing is not inventing something new with Starliner. This is a capsule, using heritage engineering first invented in the late 1950s. It should not be so hard to get this right.

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Starliner launch scrub: 13 of 24 of the capsule’s propulsion valves failed to work

9:23 am

It now appears that the launch scrub last week of Boeing’s Starliner second unmanned demo flight to ISS occurred because thirteen valves in the capsule’s propulsion valves all failed to open during prelaunch testing.

Over the weekend, the team made “positive progress,” a spokesperson said Monday, allowing the company to continue to plan for a launch this month. The company has found “no signs of damage or external corrosion,” Boeing said in a statement Monday. “Test teams are now applying mechanical, electrical and thermal techniques to prompt the valves open.” As a result, more than half of the valves “are now operating as designed,” it said, and work would continue on the others “in the days ahead.”

In a blog post, NASA said that “if all valve functionality can be restored and root cause identified, NASA will work with Boeing to determine a path to flight for the important uncrewed mission to the space station.” The earliest opportunity would come in mid-August, it said.

But Boeing still does not know what caused the valves to remain closed when they needed to be in the open position, and it is unclear how long determining that would take. As a result, some in the aerospace industry are skeptical the company could launch this month.

They have managed to get seven of those thirteen valves working again.

That 13 of 24 failed to function correct strongly suggests the problem isn’t random but is instead a fundamental design problem that needs to be identified prior to launch.

That such a problem has only been discovered now, during the launch countdown, does not reflect well on Boeing or its capsule. That the problem was not noticed in the year and a half delay caused by the software problems during the first unmanned demo flight in December 2019 makes this problem even more disturbing.

In fact, it is downright shocking. It makes one wonder about Boeing’s entire operation, considering the disastrous problems the company has also had with its commercial and military airplane projects in recent years. Does the company have no quality control systems in place, at all?

I truly hope Boeing gets this fixed and Starliner flying, but right now they need to fly a number of times, including reusing a capsule a few times, before I’d recommend anyone buying a ticket.

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Starliner launch scrubbed; no launch date yet set

8:32 am

For reasons that have not yet been revealed, ULA scrubbed today’s unmanned demo test flight of Boeing’s Starliner capsule just prior to launch, rescheduling the launch for tomorrow.

The launch tomorrow wiill occur at 12:57 am (Eastern).

UPDATE: It appears the scrub occurred because of a valve issue in the propulsion system of Boeing’s Starliner capsule.

“During pre-launch preparations for the uncrewed test flight of the CST-100 Starliner spacecraft, Boeing engineers monitoring the health and status of the vehicle detected unexpected valve position indications in the propulsion system,” the company said in a statement. “The issue was initially detected during check outs following yesterday’s electrical storms in the region of Kennedy Space Center.”

…The propulsion system valves in question are inside the Starliner’s service module, which has an array of rocket thrusters designed to propel the spacecraft away from its launcher during an in-flight emergency. Other thrusters on the service module are used for in-orbit maneuvers and spacecraft pointing control.

Boeing cannot afford more failures during this second demo flight. The company has been plagued with numerous debilitating technical failures during the past four years, from Starliner to its airlines. Right now the failure to get Starliner operational is losing them business in the emerging orbital tourist market. They need to get it working, and working reliably.

UPDATE: They have decided to cancel the launch plans for tomorrow, to roll the rocket back into the assembly building so they can do more tests on the capsule’s service module where the troublesome valves are.

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Nauka engines fire unexpectedly after docking; forces cancellation of Starliner launch

1:20 pm

The soap opera of the Nauka module to ISS became even more dramatic today when its engines fired unexpectedly after its docking, causing the station to shift in orbit and forcing Russian mission controllers to shut it down and fire other engines to return the station to its proper orbit.

Russia’s Roscosmos space agency attributed the issue to Nauka’s engines having to work with residual fuel in the craft, TASS news agency reported. “The process of transferring the Nauka module from flight mode to ‘docked with ISS’ mode is underway. Work is being carried out on the remaining fuel in the module,” Roscosmos was cited by TASS as saying.

It appears that because they needed to improvise the rendezvous using different engines, there is more fuel left over in Nauka than expected once it docked, and this needs to be vented safely. Somehow, instead of venting the module ignited the engines.

NASA has subsequently postponed tomorrow’s second unmanned demo launch of Boeing’s manned Starliner capsule until the agency has a clear understanding of the issue and has confirmed that Nauka’s presence is not a serious safety issue.

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Boeing and NASA set July 30th for 2nd unmanned Starliner demo mission

5:40 pm

Capitalism in space: Boeing and NASA today announced that they have now scheduled the second unmanned Starliner demo mission to ISS for July 30th.

In separate statements, the agency and the company said they were planning to launch the Starliner on a United Launch Alliance Atlas 5 at 2:53 p.m. Eastern July 30 on the Orbital Flight Test (OFT) 2 mission. A launch that day would allow the spacecraft to dock with the International Space Station on the evening of July 31.

The new launch date comes after NASA and Boeing completed an “integrated mission dress rehearsal” for the mission using a simulator at a Boeing facility in Houston. The five-day simulation covered activities starting 26 hours before launch and going through landing, including docking and undocking from the station.

Both Boeing and NASA are still hopeful that the first manned flight of Starliner can still take place before the end of this year. Whether it does or not will largely depend on how well things go on this unmanned demo flight.

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Boeing confirms next Starliner unmanned demo flight delayed until August

9:25 am

Capitalism in space: Boeing on April 17th confirmed what had already been rumored, that the second unmanned demo flight to ISS of Starliner, its manned capsule, has been delayed until August.

In a statement, Boeing said that the company and NASA are projecting the uncrewed Orbital Flight Test (OFT) 2 mission will take place in August or September. That date is “supported by a space station docking opportunity and the availability of the United Launch Alliance Atlas V rocket and Eastern Range.”

Boeing had been working toward a launch of OFT-2 in late March or early April. However, by early March, NASA officials acknowledged that was no longer likely because of delays from the replacement of avionics units on the spacecraft that were damaged by a power surge during ground tests, as well as power outages in the Houston area caused by a winter storm in February that interrupted software testing.

They still hope to make the first manned demo flight before the end of the year, assuming the summer unmanned flight goes as planned.

For Boeing, the sooner they get this capsule operational, the sooner it can start earning money by flying commercial flights. At the moment the delays have meant that SpaceX is getting all that business, with two private flights already scheduled and rumors that it will win a flight from the UAE as well. Furthermore, other commercial competitors are on the horizon, including both China and India.

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More delays to Boeing’s Starliner manned capsule schedule

9:52 am

Capitalism in space: Though no new launch date has been announced, both NASA and Boeing are now likely aiming for a summer launch of the second unmanned Starliner demo mission to ISS.

This is largely due to traffic at the International Space Station rather than the readiness of Starliner itself. Two NASA sources said the vehicle is “close” to being ready, with only a few small tests to certify the spacecraft for flight remaining. Starliner is therefore expected to be ready to fly by early summer.

The primary issue is the availability of space station docking ports fitted with an “international docking adapter,” which are used by SpaceX’s Crew Dragon, Cargo Dragon 2, and Starliner vehicles. There are presently two such ports on the station, and for NASA, the priority for access to these ports are crew rotations followed by supply missions. So the question becomes when the Starliner test flight can find an open slot on station.

It appears that they are now targeting the window of availability for either of those ports in the late July into August time period.

While this might be the main reason for this new delay, it also appears that there might be technical issues as well. In early March Boeing and NASA had announced that they were delaying this demo mission for the same scheduling reasons, but then they said they were targeting a May launch date, during a period after one manned Dragon mission had left in late April and before the next Dragon cargo mission arrived in June.

It now appears they cannot meet that window any longer, and are therefore aiming for the next, in July.

Meanwhile, the first manned Starliner demo mission appears to have also pushed back, from late this year to early next year.

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Scheduling conflicts at ISS delay Starliner unmanned demo flight till May

10:32 pm

NASA and Boeing have been forced to again delay the second unmanned Starliner demo mission to ISS due to scheduling conflicts with Soyuz and Dragon missions in April, forcing the flight to slip to May.

A Russian Soyuz capsule is set for launch April 9 from the Baikonur Cosmodrome in Kazakhstan with two Russian cosmonauts and a U.S. astronaut. The Soyuz MS-18 spacecraft will dock with the space station about three hours after launch, and an outgoing three-person crew will depart and return to Earth on April 17.

SpaceX’s next Crew Dragon flight to the space station is set for launch from NASA’s Kennedy Space Center in Florida around April 20 with astronauts Shane Kimbrough, Megan McArthur, Akihiko Hoshide, and Thomas Pesquet. Their mission, known as Crew-2, will last about six months.

The four astronauts who flew to the station last November on the Crew-1 mission — aboard the Crew Dragon “Resilience” spacecraft — will return to Earth in late April or early May. Both docking ports capable of receiving the Boeing Starliner capsule will be occupied during the crew handover in late April.

They had hoped to launch on April 2nd, but I suspect strongly that Boeing and NASA are glad to have this extra time.

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Texas power outages delay Starliner but not Starship

8:42 am

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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Boeing and NASA delay again the 2nd unmanned demo flight of Starliner

12:23 am

Boeing and NASA yesterday announced that they now plan to fly the second unmanned demo flight of Starliner in late March, rather in January as last scheduled.

Though there have been hints for awhile that a launch close to the start of the new year was no longer likely, this announcement confirms those hints. This means that it will have taken Boeing more than a year to fix the software issues that forced the first demo mission to abort its docking with ISS and come back early.

Whether this will delay the manned mission, which they are still targeting for as early as the summer of ’21, remains unclear. I think it will all depend on how well that the demo mission goes.

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Boeing hires former SpaceX software engineer

9:52 am

Capitalism in space: Boeing has hired a former SpaceX software engineer to head software development for the company.

Boeing on Friday announced it hired Jinnah Hosein as vice president of software engineering, a new role at the aerospace giant. The job will lead a centralized organization of engineers developing software across Boeing’s portfolio of products. Hosein will report to Greg Hyslop, Boeing chief engineer and senior vice president of engineering, test and technology.

…Hosein’s resume reads like a defense industry wish list of Silicon Valley stops. He worked as Google’s director of software engineering for cloud networking, helped design Tesla’s autopilot software and most recently worked as software lead for self-driving startup Aurora.

But it’s his experiences at SpaceX — where he was key to software development for the Falcon, Falcon Heavy, Dragon and Crew Dragon vehicles — that Boeing may look to draw from the most. Boeing and SpaceX have fiercely competed over NASA’s manned space programs, and SpaceX is a competitor for military space launches against the United Launch Alliance, which is co-owned by Boeing and Lockheed Martin.

Since software was the main issue that grounded Boeing’s 737-Max airplane as well as caused the serious problems on the first unmanned demo flight of the company’s Starliner capsule, this hire appears to be aimed at fixing these software issues. In both cases the management philosophy behind developing and testing software was very flawed, leaving the product saddled with software that either didn’t work properly or was not tested properly in development.

I imagine Boeing’s top management is hoping Hosein can bring to Boeing some of the agile, focused, and very successful management style found at SpaceX.

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Starliner Commander steps down from first manned mission

9:19 am

Capitalism in space: Boeing’s company astronaut chosen to command the first manned mission of its Starliner capsule has stepped down because the flight would prevent him from attending his daughter’s wedding next year.

In a video posted to his Twitter account, Ferguson said it was a difficult decision, but “next year is very important for my family.” He said he has several commitments “which I simply cannot risk missing.” A Boeing spokeswoman confirmed one is his daughter’s wedding. “I’m not going anywhere. I’m just not going into space next year,” Ferguson said. He stressed that he remains committed to the Starliner program and will continue to work for Boeing.

This is the second crew change for this mission. Earlier NASA astronaut Eric Boe had had to back out due to medical reasons.

Assuming the second unmanned Starliner demo mission scheduled for the December-January timeframe succeeds, the first manned mission will happen in June ’21, and last anywhere from two weeks to six months.

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Next Starship test flight to go to 60,000 feet

9:15 am

Capitalism in space: SpaceX has decided, after two successful 500 foot hops using its fifth and sixth Starship prototypes, to forego further hops with those prototypes and instead test fly prototype number eight to a height of 60,000 feet, about 11 miles.

Starship SN5 and SN6 were set to become a tag-team, flying 150-meter hops to refine the launch and landing techniques that SpaceX has pioneered with its Falcon 9 rocket. However, with SN5’s hop proving to be a success, followed by a notable improvement with SN6’s leap to 150 meters a few weeks later, it’s likely SpaceX is now confident of advancing to the next milestone.

The company has applied for an FCC license to do the flight anytime from Oct ’20 to April ’21, with October 11th being the first available date.

In the meantime the company plans a pressure tank test to failure of prototype #7, probably later this week.

In other related news at the second link, Boeing and Firefly have also applied for FCC licenses, the former for a Starliner demo mission from November ’20 to May ’21, the latter for its first launch of its smallsat Alpha rocket, also from November ’20 to May ’21.

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NASA/Boeing set summer ’21 for first manned Starliner mission

4:00 pm

Capitalism in space: NASA and Boeing have tentatively scheduled the launch of the first manned Starliner mission to ISS for the summer of 2021.

Boeing Co said on Tuesday it aims to redo its unmanned Starliner crew capsule flight test to the International Space Station (ISS) in December or January, depending on when it completes software and test hardware production development.

If the test mission is successful, Boeing and NASA will fly Starliner’s first crewed mission in summer 2021, with a post-certification mission roughly scheduled for the following winter, the company added.

Everything of course depends on the success of the unmanned demo flight. If the capsule has any further problems, as it did on its first unmanned demo flight, the manned flight will likely be delayed again.

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NASA completes Starliner review, finds more issues

9:15 am

Capitalism in space: NASA yesterday released the results of its investigation into the issues that prevented Boeing’s manned Starliner capsule from successfully completing its unmanned demo flight to ISS in December, finding an additional 20 issues over the 61 initially identified shortly after the mission.

In closing out the seven-month investigation, NASA officials said Tuesday they have now identified 80 corrective actions, mostly involving software and testing, that must be done before the Starliner capsule launches again. The previous count was 61.

NASA officials also admitted that they had been so focused on making sure SpaceX’s Dragon capsule was going to work that they became lax in reviewing Boeing’s work. Now they not only are going to focus more on Boeing, they actually want to use SpaceX’s approach to software development throughout NASA.

NASA is also borrowing SpaceX’s “robust” approach to software, which involves going back to the designers following testing for feedback, said Kathy Lueders, NASA’s new human spaceflight chief who until a month ago managed commercial crew. She wants to see more of that type of approach across other NASA programs.

Though it seems absurd and incredible that NASA has not been consulting with its designers after testing, it is also not surprising. When it comes to designing and building anything at NASA the management processes there have routinely done a bad job for many years.

As for Starliner, it is expected it will take a few more months to fix these issues, which means the next unmanned test flight is likely still set for sometime in the fall, with the manned mission to follow next spring.

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Boeing’s Starliner aces parachute test

9:26 am

Capitalism in space: Boeing last week successfully completed a Starliner parachute test designed to simulate the return of a capsule after a launch abort.

This is good news for the capsule and Boeing, but I am a bit puzzled why this test, to be followed by a second similar test, was done. These parachutes were supposedly tested thoroughly already, proven, and ready for use for manned missions. Part of that proof was an earlier launch abort test as well as Boeing’s unmanned orbital demo flight that failed to dock with ISS. Both returned to Earth safely using these parachutes. I wonder if during those latter flights they found issues with the parachutes that needed smoothing out by even more tests.

Either way, this success improves the chances that Starliner will finally fly manned early next year, giving the U.S. two different operational manned capsules for getting humans into space.

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Boeing to do second unmanned test flight of Starliner

12:59 am

Capitalism in space: Boeing officials said yesterday that they now plan a second unmanned demo mission to ISS of their Starliner manned capsule in order to make sure they have cleared up all the issues that plagued the first unmanned flight in December.

The company on Monday confirmed a report in the Washington Post that it will fly a second uncrewed demonstration mission — which Boeing calls an Orbital Flight Test — before astronauts ride a Starliner into orbit.

“We have chosen to refly our Orbital Flight Test to demonstrate the quality of the Starliner system,” Boeing said in a statement Monay. “Flying another uncrewed flight will allow us to complete all flight test objectives and evaluate the performance of the second Starliner vehicle at no cost to the taxpayer. We will then proceed to the tremendous responsibility and privilege of flying astronauts to the International Space Station.”

Right now they are aiming for an October/November launch date.

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