Tag: ULA

Space Force awards SpaceX big launch contract

10:24 am

Space Force yesterday awarded SpaceX a $733 million contract for what appears to be a total of eight future launches of military and national security payloads.

Few details were released about the payloads, including the launch timeline. The deal was issued as part of the military launch contracting system, which in June named SpaceX, ULA, and Blue Origin as its launch providers for the next five years.

However, one official’s comment appeared to suggest this contract award was the military’s expression of disgust at the delays at ULA and Blue Origin in getting their rockets launchworthy.

“In this era of Great Power Competition, it is imperative to not leave capability on the ground,” Brig. Gen. Kristin Panzenhagen, program executive officer for Assured Access to Space, said in an emailed statement on Friday. “The Phase 3 Lane 1 construct allows us to execute launch services more quickly for the more risk-tolerant payloads, putting more capabilities on orbit faster in order to support national security,” Panzenhagen added. [emphasis mine]

In other words, the Space Force wanted to split this contract between the three companies, but it decided to give it all to SpaceX because it expected any launches given to ULA and Blue Origin would not launch on time, and it didn’t want “to leave [that] capability on the ground.”

In the case of ULA, its Vulcan rocket finally made its first two launches this year, four years late, but on the second launch had a failure on one of its solid-fueled strap-on boosters (the nozzle fell off). Though the rocket successfully placed its dummy payload into the correct orbit, the military has either decided that it can’t yet certify Vulcan for military launches, or sees further delays while the investigation and fixes are installed.

As for Blue Origin, its New Glenn rocket is also four years behind schedule, and likely won’t launch until next year. To get it certified will also probably require two launches, and since that company never seems to be in a hurry to do anything (NASA removed its payload from New Glenn’s first launch because the company had failed to meet the required interplanetary launch window), the Pentagon probably decided it can’t give it any contracts at this time.

And so, more launches and profits for SpaceX. While it is great for that company, with revenue that will likely aid in developing Starship/Superheavy, this is not a healthy situation for the American space industry. As a nation we need more than one launch provider. We need these other companies to stop dithering around and get the job done. That’s the true American way. Have they forgotten how to do it?

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ULA recovers nozzle debris that fell off during second Vulcan launch

9:05 am

ULA has recovered some of the debris that fell to earth after the nozzle on one of Vulcan’s two solid-fueled strap-on boosters fell off during the early stages of the rocket’s second launch on October 4, 2024.

Julie Arnold, a ULA spokesperson, confirmed to Ars that the company has retrieved some of the debris. “We recovered some small pieces of the GEM 63XL SRB nozzle that were liberated in the vicinity of the launch pad,” Arnold said. “The team is inspecting the hardware to aid in the investigation.”

The booster was built by Northrop Grumman. Vulcan can use from from two to six on each flight (in pairs), depending on the mass of its payload and the mission requirements. At the moment ULA has 35 of these boosters in storage awaiting future flights. It is expected that once the company has an idea of the root cause of the failure, it will have to inspect each booster to avoid a repeat of the problem.

Though ULA has not announced any changes in its plans to launch twice more before the end of the year, both for the Pentagon, that schedule is now uncertain due to this problem. For example, there as yet is no word on whether the military is willing to certify the launches. It had required ULA to complete two test flights of Vulcan before doing so, and the nozzle issue has cast a cloud on that plan.

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FAA and the Biden administration proves it is out to destroy SpaceX

9:47 am

The FAA to SpaceX
The FAA to SpaceX “Nice company you got here.
Sure would be a shame if something happened to it.”

In the past week the FAA proved unequivocally that it is abusing its regulatory powers for political reasons, imposing much harsher regulatory restrictions on SpaceX while allowing other companies much more free rein.

That reality became most evident first with the FAA response to the serious failure of one of the strap-on solid-fueled boosters during the second test launch of ULA’s Vulcan rocket on October 4, 2024. During that launch something went seriously wrong with that booster 38 seconds after launch, involving an explosion and what appeared to be ejection of that booster’s nozzle. Though the launch succeeded in placing its payload into the correct orbit, it required the rocket’s main engines to compensate aggressively.

Despite this, the FAA decided no investigation by it was necessary.

The Federal Aviation Administration, which licenses commercial space launches in the United States, said in a statement that it assessed the booster anomaly and “determined no investigation is warranted at this time.” The FAA is not responsible for regulating launch vehicle anomalies unless they impact public safety.

This decision is correct, but the contrast with the FAA’s treatment of SpaceX is quite striking. If the FAA applied the absurd standard it has been using against SpaceX, it would claim that this Vulcan launch threatened public safety because the incident occurred 38 seconds after launch and was thus relatively close to Florida, where an out of control rocket could potentially threaten public safety.

Such a threat of course really doesn’t exist, as the FAA correctly concluded, because the rocket has a self-destruct system to prevent it from crashing in habitable areas.

Yet the agency failed to use this logic with SpaceX. Instead the FAA decided anything SpaceX launches that doesn’t work perfectly poses a serious public safety threat, no matter where or how it happens, and thus has repeatedly grounded SpaceX launches. A first stage, flown already 23 times, falls over after soft-landing successfully on its drone ship in the middle of the Atlantic, and somehow this justified the FAA grounding SpaceX due to the threat to public safety. A second stage, after successfully placing two astronauts into orbit, misfires during its de-orbit burn but still lands in the middle of the ocean, far from any habitable regions, and somehow this justified the FAA grounding SpaceX due to the threat to public safety.

And the fact that a Superheavy returning to its launchpad at Boca Chica will cause a sonic boom — as do every Falcon 9 landings at Cape Canaveral or Vandenberg — is now justification for grounding Starship/Superheavy test launches, even though sonic booms pose zero threat to anyone other than startling them with the sudden noise.

The FAA further illustrated its bias against SpaceX when it decided to allow the company to do its launch this morning of Europe’s Hera asteroid mission, but specifically stated that the company’s other launches remain grounded.
» Read more

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ULA successfully completes second test launch of its new Vulcan rocket

8:36 am

ULA this morning successfully completed the second test launch of its new Vulcan rocket, lifting off from Cape Canaveral from Florida.

It placed a dummy test payload into orbit in order to obtain from the Space Force certification that will allow the company to begin operational military launches and actually make money from the rocket. ULA hopes to launch two such Vulcan launches before the end of the year, and then hopes to do ten more Vulcan launches in 2025, along with ten Atlas-5 launches as it closes out that rocket’s inventory before retiring it.

UPDATE: An explosion on of Vulcun’s two solid-fueled strap-on boosters during the launch today might prevent a quick certification from the military. Though the rocket successfully put the payload into its correct orbit, it appears the nozzle failed on that booster, throwing it out sideways, fortunately away from the rocket. The video here shows this clearly. I was startled by this explosion during the launch, but then forgot about it (until my readers reminded me) when the payload reached orbit as planned.

The strap-on boosters are manufactured by Northrop Grumman. Before using them again ULA needs to get clarity on this issue. We also must wonder if the FAA will step in as it has for SpaceX to ground ULA. At the moment it has decided not to do so.

This was ULA’s fifth launch in 2024, so there is no change in the 2024 launch race leader board.

95 SpaceX
44 China
11 Russia
11 Rocket Lab

American private enterprise now leads the rest of the world combined in successful launches 112 to 67, while SpaceX by itself now leads the entire world, including American companies, 95 to 84.

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ULA’s big plans for 2025

12:31 pm

As ULA prepares for the second launch of its new Vulcan rocket, presently scheduled for launch tomorrow at 6 am (Eastern), it held a press briefing on October 2, 2024 to provide an update on the rocket’s present and future status.

The key takeaways, assuming this launch succeeds as planned, as noted in a tweet by reporter Jeff Foust from Space News:

  • ULA still plans on completing two national security Vulcan flights before the end of the year
  • It is targeting 20 launches in 2025, half with Vulcan and half with Atlas-5
  • The first Atlas-5 launch of Amazon’s Kuiper satellites won’t happen until 2025
  • When Sierra Space says Dream Chaser is ready, ULA will launch it

Completing three Vulcan launches in the next three months will almost match the four launches the company has so far completed in the first nine months of the year. Furthermore, considering that ULA’s previous record for launches in a single year is 16, set in 2009, and that the company has not completed more than ten launches in a year since 2016, these plans are very ambitious indeed.

If it succeeds however in just getting close to these numbers, ULA will be doing very well indeed.

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Sierra Space in negotiations to buy ULA

10:26 pm

According to the Reuters news agency, Sierra Space is negotiating with the joint owners of ULA, Boeing and Lockheed Martin, to buy the rocket company.

The sources, which are all anonymous, said the sale price is in the range of $2 to $3 billion. Those same sources said no deal has yet been worked out, and might not happen at all.

For Sierra, the deal would give it its own launch vehicle, Vulcan, for placing its Dream Chaser mini-shuttles into orbit. It would also give it a profit stream from the many military and commercial launch contracts already on ULA’s manifest. The combined cababilities of ULA and Sierra will create a formidable new player in the aerospace launch market.

For Boeing, it would provide it some much needed cash that it will be able to use to both restructure and revitalize its presently questionable operations.

It is unclear what Lockheed Martin will gain from the sale, other than the cash and the removal of this Frankenstein-like partnership with Boeing, which in the long run has probably not done it a lot of good.

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ULA losing launch crews to other rocket companies

9:23 am

ULA, which hopes to set a company launch record next year, is right now suffering a major loss of its launch crews to SpaceX and Blue Origin.

This year alone, ULA has lost about 45 of its 105 Launch Operations engineers — the people who test, assemble and prepare every rocket and its cargo to fly — at its primary launch site in Florida, according to the person, who asked not to be identified discussing non-public information. The lack of experienced personnel has postponed work for future missions, the person said.

The article says the loss of these launch crew employees is because of higher pay offered by the other companies, but I suspect a contributing factor is ULA’s low rate of launches in recent years (3 in 2023 and 4 so far in 2024). These people have nothing to do, and see the lack of work as detrimental to their future careers. Better to move on, either to SpaceX where a lot of launches occur, one almost every other day, or to Blue Origin, where the rocket is new and the company has plenty of cash.

The flight of crews could also be because people do not see a future at ULA. For almost a year there have been rumors that Boeing and Lockheed Martin, which own it jointly, want to sell it. It was thought that sale would happen after the first Vulcan rocket launch, but it did not. In recent months those rumors have subsided, suggesting that the interest in buying the company has trailed off.

Despite these problems, ULA’s problems could very well be temporary. Its manifest has a lot of launches scheduled, and once Vulcan is certified for the military and operational for all its customers, it is expected to be launching more than twice a month next year. If those launches take place as planned, these issues will be begin to vanish very quickly.

In fact, it does appear that if you are an engineering student with an interest in rocketry, your future is extremely bright. There will be plenty of work opportunities for you in Florida in the future, from any one these companies.

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SpaceX’s new Raptor-3 methane-fueled engine is so advanced the CEO of ULA doesn’t understand it

12:31 pm

SpaceX's new Raptor-3 engine
Click for original image.

When Elon Musk on August 2, 2024 proudly tweeted a picture of SpaceX’s new Raptor-3 methane-fueled engine, the third iteration of the engine it uses on this Starship/Superheavy rocket, Tori Bruno, the CEO of ULA, looked at the image (to the right) and complained that Musk and SpaceX were touting pictures of a “partially assembled engine.” As Bruno tweeted:

They have done an excellent job making the assembly simpler and more producible. So, there is no need to exaggerate this by showing a partially assembled engine without controllers, fluid management, or TVC systems, then comparing it to fully assembled engines that do.

It turns out that this engine is so advanced that Bruno — the CEO of SpaceX’s best competitor — didn’t understand it. Both Musk and SpaceX’s CEO Gywnne Shotwell immediately responded with images of this same engine operating during hot fire tests. As Shotwell tweeted, “Works pretty good for a ‘partially assembled’ engine :).”

Musk in one of his first tweets describing the engine’s specifications was also right when he described it as “Truly, a work of art.” Look at it. For what is the most powerful rocket engine ever built it looks as streamlined and a simple as the slant-6 car engine I had in my 1969 Plymouth Valient, built long before environmental regulations caused car engines to become incredibly overbuilt and complicated.

This little anecdote illustrates quite starkly how advanced SpaceX is over its competitors. It is now building rocket engines with technology beyond the immediate understanding of the CEO of the United States’ second largest rocket company.

Almost a decade after SpaceX successfully reused a Falcon 9 first stage, and now does it routinely, no other rocket company as yet to do the same, and only one company, Rocket Lab, is doing flight tests in an attempt to eventually do so.

SpaceX has no competition because too many of its competitors are simply not trying to compete. It is both sad and shameful.

Hat tip to reader Rex Ridenoure.

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ULA squelches independent photography of its launches

10:27 am

For reasons that appear fundamentally stupid, ULA early in July announced that it will now forbid independent freelance photographers who use the remote sites inside the launch facility at Cape Canaveral from selling their pictures independently.

The language was clear: Photographers were welcome to set up remote shots at ULA launches if they worked for the media or wanted to post their work on social media. However, photographers could not sell this work independently, including as prints for fellow enthusiasts or for use in annual calendars.

“ULA will periodically confirm editorial publication for media participating in remote camera placement,” the email stated. “If publication does not occur, or photos are sold outside of editorial purposes, privileges to place remote cameras may be revoked.”

In other words, photographers who come to Cape Canaveral to take pictures will only be allowed to do so it they are working for professional media, or are selling their work to news outlets. Photographers who make a living selling prints to collectors, or simply post them on social media in order to garner traffic, will eventually lose their access to the sites.

The article suggests this policy was instituted because managing the number of photographers had become unwieldy, but that is a pure guess, since ULA has not provided any explanation, nor has it responded to any questions from other press outlets.

From a PR point of view, this decison by ULA makes no sense. All it does is antagonize the public and the press, while reducing its public footprint. In this age of social media, publicity comes not just from major media outlets, but from the independent individuals writing for their own websites or X feeds.

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ULA completes its 4th launch this year and last Atlas-5 launch for the Space Force

9:10 am

Though ULA’s Atlas-5 rocket still has a number of launches on its manifest before it is retired, early this morning the company successfully completed the last Atlas-5 launch for the Space Force, the rocket lifting off from Cape Canaveral in Florida.

This was ULA’s fourth launch in 2024, the most in a year for the company since 2022. The leader board for this year’s launch race remains unchanged:

74 SpaceX
31 China
8 Rocket Lab
8 Russia

American private enterprise however now leads the rest of the world combined in successful launches 87 to 47, while SpaceX by itself still leads the entire world combined, including American companies, 74 to 60.

Note: A Rocket Lab that had been scheduled for today has been delayed two days.

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ULA replaces Sierra’s mini-shuttle with dummy payload to launch Vulcan in September

9:28 am

Because of continuing delays in preparing Sierra Space’s Tenacity Dream Chaser mini-shuttle for launch, ULA has been forced to remove it from the second launch of Vulcan in order to proceed with the launch in September as planned.

ULA needs to launch Vulcan for the second time and as soon as possible in order to get approval from the Pentagon to do military launches. The delays in getting Tenacity ready for launch has already impacted that schedule, as ULA had originally hoped to launch Vulcan on its second flight — with Tenacity as the payload — several months ago. Further delays beyond September would seriously damage not only ULA’s bottom line, but the military’s own needs. It is all for these reasons that ULA has now set up a new review team to force this schedule forward, likely under pressure from the Pentagon.

Sierra Space meanwhile says that Tenacity is still on track to be ready to launch before the end of the year, but it is unclear what rocket will carry it. ULA will likely offer another Vulcan rocket for the purpose, but to do so it will probably have to delay some other payload, and it is certain it will not do that to any upcoming military launches. Based on the announced launch schedule, it does not look like this launch can occur on a ULA rocket in 2024. ULA says it hopes to launch at least 20 times in 2025, so one of those launches will likely carry Tenacity.

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Space Force names SpaceX, ULA, and Blue Origin as its launch providers for the next five years

9:14 am

As part of the military’s program for issuing launch contracts, the Space Force yesterday announced that it has chosen SpaceX, ULA, and Blue Origin as its launch providers, allowing them to bid on $5.6 billion worth of planned launched over the next five years.

The NSSL Phase 3 program was structured into two “lanes.” Lane 1 is for less demanding launches to low Earth orbit, while Lane 2 is reserved for heavy lift rockets capable of delivering payloads to nine reference orbits, including some of the most demanding national security missions.

The selection of Blue Origin, SpaceX, and ULA for Lane 1 contracts confirms that no other launch providers met the criteria. Seven bids were submitted, according to the DoD announcement.

The Space Force apparently rejected the other four unnamed companies because they “are still maturing their launch capabilities.” It will allow them to re-submit applications next year, and could approve others for bidding at that time, which is a major change from past policy. Previously the military would name approved companies, but not reconsider others for years, a policy that limited its options and reduced competition. Now it appears it will be doing so frequently, possibly every year, in order to regularly increase the number of companies that can bid on military contracts.

This change is excellent news for the American launch industry, as it means the Pentagon has finally ended its long standing launch policy that played favorites.

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ULA’s Atlas-5 launches Boeing’s Starliner capsule on its first manned mission

9:17 am

After many delays and scrubs involving both the rocket and the capsule, ULA’s Atlas-5 rocket today successfully launched Boeing’s Starliner capsule on its first manned mission, carrying NASA astronauts Butch Wilmore and Suni Williams.

I have embedded the live stream below, cued to just before liftoff. The spacecraft will dock with ISS tomorrow, where Wilmore and Williams will spend a week checking out the capsule’s operations before undocking and returning to Earth.

As this was only the third launch this year for ULA, the leader board for the 2024 launch race doesn’t change:

59 SpaceX
26 China
8 Russia
7 Rocket Lab

American private enterprise now leads the world combined in successful launches, 69 to 40, while SpaceX by itself leads the entire world, including other American companies, 59 to 50.

» Read more

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NASA confirms June 5th as new launch date for Starliner

8:33 am

NASA yesterday evening confirmed that the agency, ULA, and Boeing are now targeting June 5, 2024 at 10:52 am (Eastern) for the launch of the first manned launch of Boeing’s Starliner capsule carrying two astronauts to ISS for a two week checkout mission.

Technicians and engineers with ULA (United Launch Alliance) worked overnight and on Sunday to assess the ground support equipment at the launch pad that encountered issues during the countdown and scrubbed the June 1 launch attempt. The ULA team identified an issue with a single ground power supply within one of the three redundant chassis that provides power to a subset of computer cards controlling various system functions, including the card responsible for the stable replenishment topping valves for the Centaur upper stage. All three of these chassis are required to enter the terminal phase of the launch countdown to ensure crew safety.

On Sunday, the chassis containing the faulty ground power unit was removed, visually inspected, and replaced with a spare chassis. No signs of physical damage were observed. A full failure analysis of the power unit will be performed to better understand root cause. Meanwhile, ULA has completed functional checkouts of the new chassis and the cards, and all hardware is performing normally.

These kinds of technical issues happen too often on ULA launches. Company engineers always fix them, but it never appears they fix them permanently. Too often on launches they pop up again, causing more scrubs.

The goal should be to fix them so they never pop up again, and your launches can begin to launch reliably, on time. And we know it can be done, because SpaceX has done it.

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Boeing Starliner launch scrubbed at T-3:50

10:10 am

UPDATE: The launch is now scheduled for June 5, 2024 at 10:52 am (Eastern).

For reasons that appeared related to the ground system’s of ULA’s Atlas-5 rocket, the first manned launch of Boeing’s Starliner’s capsule was scrubbed today at T-3:50.

It appears they want to try again tomorrow at 12:03 pm (Eastern), assuming ULA can figure out what happened.

The repeated scrubs and delays that have so far prevented this launch are beginning to remind my of my childhood watching the early NASA launch attempts during the Mercury program. Then, they hadn’t done this before, and were being very careful about everything.

Now, it seems that NASA, ULA, and Boeing are acting the same way, and that is probably because they are very nervous about Starliner and don’t want anything to go wrong.

I had intended to embed the live stream, but slept late (it IS the weekend, y’know). Sorry.

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Watching the first manned launch of Boeing’s Starliner capsule

9:31 am

NASA has now announced the broadcast schedule for tomorrow’s 12:35 pm (Eastern) launch of Boeing’s Starliner capsule on its first manned mission to ISS.

NASA will provide live coverage of prelaunch and launch activities for the agency’s Boeing Crew Flight Test, which will carry NASA astronauts Butch Wilmore and Suni Williams to and from the International Space Station.

Launch of the ULA (United Launch Alliance) Atlas V rocket and Boeing Starliner spacecraft is targeted for 12:25 p.m. EDT Saturday, June 1, from Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida. Starliner will dock to the forward-facing port of the station’s Harmony module at approximately 1:50 p.m., Sunday, June 2.

The live stream will begin on NASA TV at 8:15 am (Eastern). I will embed that live stream here tomorrow. As this start time is more than four hours before launch, expect there to be endless NASA propaganda for most of that time. My advice is to tune in at around noon.

Let us all pray that all goes well on this flight. Boeing’s recent track record has generally be horrible. We can only hope its engineers have gotten all of the kinks out of this capsule.

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NASA/Boeing/ULA confirm new June 1st launch date for Starliner

9:36 am

In a press briefing this morning officials from NASA, Boeing, and ULA confirmed the new June 1, 12:25 pm (Eastern) launch date for the first manned flight of Boeing’s Starliner manned capsule.

The officials provided a more detailed explanation of the helium leak in a valve that effects the capsule’s service module attitude thruster system, noting that it is not a design flaw but some specific issue in this particular valve. Because of this, they are confident the system can function safely even with the leak, which is relatively small.

However, the officials also noted that during their reviews in the past two weeks they discovered a new software issue in the spacecraft’s de-orbit engines that — under very unusual and unlikely circumstances — could actually cause those engines to fail to operate. They have figured out a work-around, whereby they fire the engines at a lower thrust in two stages rather than once.

Should the launch on June 1st be scrubbed for weather, they have back up dates on the next few days, though by June 4th ULA might have to swap out batteries on its Atlas-5 rocket that will require a longer stand down of several additional days.

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Boeing/NASA now targeting a June 1, 2024 launch of Starliner

9:28 am

In a brief update posted today by NASA, the agency announced that Boeing, NASA, and ULA have a new 12:25 pm (Eastern) June 1, 2024 launch date for the first manned flight of Boeing’s Starliner capsule.

The announcement was incredibly obscure about what the issues are that have caused this additional week delay:

Work continues to assess Starliner performance and redundancy following the discovery of a small helium leak in the spacecraft’s service module. As part of this work, and unrelated to the current leak which remains stable, teams are in the process of completing a follow-on propulsion system assessment to understand potential helium system impacts on some Starliner return scenarios. NASA also will conduct a Delta-Agency Flight Test Readiness Review to discuss the work that was performed since the last CFT launch attempt on May 6, and to evaluate issue closure and flight rationale ahead of the next attempt, as part of NASA’s process for assessing readiness. The date of the upcoming Flight Test Readiness Review is under consideration and will be announced once selected.

It appears that engineers are worried the leak — which is linked to one of the attitude thrusters in the capsule’s service module — might impact the ability of Starliner to return to Earth safely. It also appears there is concern about the spacecraft sitting on the launchpad for more than a month, and an evaluation is on-going on whether this might be an issue as well.

I am guessing however. A more detailed explanation might be forth-coming after press update scheduled for 11 am (Eastern) tomorrow.

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Starliner manned launch delayed again; no new launch announced

9:33 am

In a very terse statement that apparently was only sent out by email to some sources, NASA and Boeing announced last night that the May 25, 2024 launch of the first manned Starliner mission on ULA’s Atlas-5 rocket had been postponed, with no new launch date set.

NASA, Boeing, and ULA are foregoing the Saturday, May 25 launch attempt for NASA’s Boeing Crew Flight Test. The team has been in meetings for two consecutive days, assessing flight rationale, system performance, and redundancy. There is still forward work in these areas, and the next possible launch opportunity is still being discussed.

NASA will share more details once we have a clearer path forward,

The first launch scrub prior to the first launch date of May 6th was due to a valve issue on the Atlas-5 rocket. ULA quickly replaced that valve and the launch was rescheduled for May 17th. Then Boeing engineers detected a helium leak related to one of the attitude thrusters in the capsule’s service module. The launch was first delayed until May 21st, then delayed again until May 25th. Now it is delayed indefinitely.

Whether that helium leak remains the cause of this new delay remains unknown. That no new launch date has been proposed suggests the need to bring the rocket and capsule back to the assembly building to destack it in order to fix the problem. That NASA, Boeing, and ULA are being so coy about revealing any details suggests however that some additional issue might have been uncovered.

Regardless, this new extended delay is very bad publicity for Boeing. While the comparison is somewhat unfair, it continues to make Starliner look like an American version of a Yugo, not the kind of vehicle one would nonchalantly climb into for a flight into space.

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Sierra Space’s Tenacity mini-shuttle arrives at the Cape

9:30 am

Capitalism in space: Sierra Space’s Tenacity Dream Chaser mini-shuttle has finally arrived at the Kennedy Space Center in Florida for its final testing and assembly onto ULA’s Vulcan rocket.

Upon arrival at Kennedy, teams moved Dream Chaser Tenacity to the high bay inside the Space Systems Processing Facility, where it will undergo final testing and prelaunch processing ahead of its launch scheduled for later this year.

…The remaining pre-flight activities at Kennedy include acoustic and electromagnetic interference and compatibility testing, completion of work on the spaceplane’s thermal protection system, and final payload integration.

If all goes right, Tenacity’s first mission will last 45 days, delivery about 7,800 pounds of cargo to ISS, and prove out the reusable mini-shuttle for up to seven more flights to ISS.

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Starliner launch delayed again, to May 25, 2024

3:36 pm

Boeing, ULA, and NASA have decided to delay the first manned flight of Boeing’s Starliner capsule another four days to 3:09 pm (Eastern) on May 25, 2024.

The additional time allows teams to further assess a small helium leak in the Boeing Starliner spacecraft’s service module traced to a flange on a single reaction control system thruster. Pressure testing performed on May 15 on the spacecraft’s helium system showed the leak in the flange is stable and would not pose a risk at that level during the flight. The testing also indicated the rest of the thruster system is sealed effectively across the entire service module. Boeing teams are working to develop operational procedures to ensure the system retains sufficient performance capability and appropriate redundancy during the flight.

It appears they simply want to give themselves extra time to review their data thoroughly, with no rush, before lighting the rocket.

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Atlas-5 launch of Starliner slips to May 21, 2024

1:25 pm

While ULA has successfully replaced the valve in the upper stage of the Atlas-5 rocket, the first manned launch of Boeing’s Starliner capsule has slipped another four days, to May 21, 2024, because a newly discovered helium leak in the capsule’s service module.

Starliner teams are working to resolve a small helium leak detected in the spacecraft’s service module traced to a flange on a single reaction control system thruster. Helium is used in spacecraft thruster systems to allow the thrusters to fire and is not combustible or toxic.

NASA and Boeing are developing spacecraft testing and operational solutions to address the issue. As a part of the testing, Boeing will bring the propulsion system up to flight pressurization just as it does prior to launch, and then allow the helium system to vent naturally to validate existing data and strengthen flight rationale.

The prevous launch scrub was entirely due to the ULA’s rocket, not anything related to Boeing. This delay however is a Boeing issue, and it only reinforces the general uneasiness everyone feels about Boeing’s quality control work.

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Air Force sends letter of concern about Vulcan to ULA

10:21 am

According to a report yesterday [behind a paywall], the Air Force has sent a letter of concern to ULA and its joint owners, Boeing and Lockheed Martin, about the long delays getting its new Vulcan rocket operational.

When the military chose in 2021 ULA and SpaceX to be its two launch providers for the first half of the 2020s, it expected ULA to complete 60% of the launches and SpaceX 40%. It also expected Vulcan to being launching within a year or two, at the latest.

Instead, the first launch of Vulcan did not occur until 2024, and its second launch — required by the military before it will allow Vulcan to launch its payloads — won’t occur until late this year. Worse, the military has a large backlog of launches it has assigned to Vulcan that need to launch quickly.

“I am growing concerned with ULA’s ability to scale manufacturing of its Vulcan rocket and scale its launch cadence to meet our needs,” [Air Force Assistant Secretary Frank] Calvelli wrote. “Currently there is military satellite capability sitting on the ground due to Vulcan delays. ULA has a backlog of 25 National Security Space Launch (NSSL) Phase 2 Vulcan launches on contract.”

These 25 launches, Calvelli notes, are due to be completed by the end of 2027. He asked Boeing and Lockheed to complete an “independent review” of United Launch Alliance’s ability to scale manufacturing of its Vulcan rockets and meet its commitments to the military. Calvelli also noted that Vulcan has made commitments to launch dozens of satellites for others over that period, a reference to a contract between United Launch Alliance and Amazon for Project Kuiper satellites.

ULA says that once operations ramp up, it plans to launch Vulcan twice a month. The Air Force doubts about whether that will be possible however are well founded. To meet that schedule ULA will need delivery per month of at least four BE-4 engines from Blue Origin, and so far there is no indication the Bezos company can meet that demand. Delays at Blue Origin in developing that engine are the main reason Vulcan is so far behind schedule in the first place.

In order to get Vulcan operational, ULA needs to fly a second time successfully. The second launch of Sierra Space’s Tenacity mini-shuttle is booked for that flight, and was originally supposed to launch this spring. Tenacity however was not ready, as it is still undergoing final ground testing. The launch is now set for the fall, but both ULA and the Pentagon are discussing replacing it with a dummy payload should Tenacity experience any more delays.

The source of all of these problems points to Blue Origin. Not only has it been unable to deliver its BE-4 rocket engine on schedule — thus blocking Vulcan — the long delays in developing its own New Glenn orbital rocket (which uses seven BE-4 engines) has given the military fewer launch options. As a result the military has been left with only one rocket company, SpaceX, capable of launching its large payloads.

To put Blue Origin’s problems in perspective, for Blue Origin to finally achieve its many promises and get both Vulcan and New Glenn flying regularly, it will need to begin producing a minimum of 50 to 150 BE-4 engines per year, with two-thirds for its own New Glenn rocket. Right now all evidence suggests the company is having problems building two per year.

In other words, the Pentagon might send a letter of concern to ULA, but it should instead be focusing its ire on Blue Origin.

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ULA signs contract to build a second transport ship for its Vulcan rocket

9:45 am

ULA yesterday announced it has issued contracts for the construction of a second transport ship for bringing its Vulcan rocket from the factory in Alabama to the launch sites in Florida and California.

ULA awarded Bollinger Shipyards a contract to build a second roll-on/roll-off vessel classed for both ocean-going and river service. Construction has just begun on the 356-ft-long ship at Bollinger’s shipyard located in Amelia, Louisiana with delivery to ULA expected in January 2026.

…“ULA currently has its first ship called RocketShip that has been in service for decades and with this second ship called SpaceShip our maritime fleet will enable enterprise transportation capacity of four Vulcan launch vehicles across two voyages to either the East or West Coast,” said Ellerhorst.

ULA also hired a company in Rhode Island to design and supervise the construction. The company needs two ships because it has a lot of launches scheduled over the next few years, including 38 for Amazon to help launch its Kuiper internet satellite constellation as well as a number the U.S. military.

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Launch of first manned flight of Starliner rescheduled for May 17, 2024

9:31 am

Because ULA engineers have decided they need to replace the valve that forced a launch scrub on May 8th, the first manned launch of Boeing’s Starliner capsule to ISS has now been rescheduled to May 17, 2024.

The oscillating behavior of the valve during prelaunch operations, ultimately resulted in mission teams calling a launch scrub on May 6. After the ground crews and astronauts Butch Wilmore and Suni Williams safely exited from Space Launch Complex-41, the ULA team successfully commanded the valve closed and the oscillations were temporarily dampened. The oscillations then re-occurred twice during fuel removal operations. After evaluating the valve history, data signatures from the launch attempt, and assessing the risks relative to continued use, the ULA team determined the valve exceeded its qualification and mission managers agreed to remove and replace the valve.

Replacing the valve is a somewhat routine procedure, but it will take a few days, causing the two-week delay.

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Starliner launch scrubbed due to valve issue

9:21 am

Yesterday’s Starliner launch was scrubbed before launch because ULA had detected an issue with a valve on the Atlas-5’s Centaur upper stage, causing that valve to flutter because it had not closed in the proper position.

At the press conference that followed, ULA’s CEO Tory Bruno explained that during an unmanned launch, engineers would have simply cycled the valve, which almost always works to get it to seat properly. ULA launch rules however forbids it from doing so on a manned launch, because that would be the equivalent of fueling the tank with people on board the rocket. The Atlas-5 was initially not built for manned flights, and though it has been upgraded to man-rate it, those upgrades did not permit ULA this capability, unlike SpaceX’s Falcon 9, which get fueled entirely after the crew boards Dragon.

They are reviewing the data to see if the valve will need to be replaced. If not, the launch could happen quickly. If it does, the launch will be delayed slightly longer, but not significantly. Right now ULA, NASA, and Boeing are targeting a May 10th launch.

It is worth listening to Tory Bruno’s explanation of the situation because of its clarity. I have embedded his comments below, time-stamped to when he began speaking.
» Read more

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NASA announces launch coverage for the first Starliner manned capsule launch on May 6, 2024

10:23 am

NASA today released the details for its public media coverage of the first manned launch at 10:34 pm (Eastern) on May 6, 2024 of Boeing’s Starliner capsule.

NASA will provide live coverage of prelaunch and launch activities for the agency’s Boeing Crew Flight Test, which will carry NASA astronauts Butch Wilmore and Suni Williams to and from the International Space Station.

Launch of the ULA (United Launch Alliance) Atlas V rocket and Boeing Starliner spacecraft is targeted for 10:34 p.m. EDT Monday, May 6, from Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida. The flight test will carry Wilmore and Williams to the space station for about a week to test the Starliner spacecraft and its subsystems before NASA certifies the transportation system for rotational missions to the orbiting laboratory for the agency’s Commercial Crew Program.

Starliner will dock to the forward-facing port of the station’s Harmony module at 12:48 a.m., Wednesday, May 8.

Though that coverage includes several prelaunch and post launch press conferences, the key coverage of the launch itself will begin at 6:30 pm (Eastern) on May 6th, about four hours before the launch itself. It will also include the capsule’s docking with ISS on May 8th.

I will embed NASA’s Youtube live stream here on Behind the Black on both dates, though as always I sugggest waiting until just before launch and docking to tune in. The four hours of streaming prior to launch is mostly going to be NASA propaganda, touting the agency and often misconstruing the facts to overstate its importance. This launch will be just like SpaceX’s Dragon launches, in that almost everything will be run by the two private companies involved, Boeing and ULA, and not NASA. NASA’s real involvement will only begin at the docking to ISS.

This first manned flight of Starliner is long past due. It was supposed to occur about four years ago, but numerous technological and management problems at Boeing forced many delays. Getting that capsule operational will finally give NASA two American companies capable of putting humans in space. It will also offer some competition to SpaceX, though this competition will be weak until Boeing can demonstrate Starliner’s reliability.

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Blue Origin completes delivery of the two BE-4 engines for ULA’s second Vulcan launch

10:04 am

Blue Origin this week completed delivery of the two BE-4 engines needed for the second launch of ULA’s Vulcan rocket, presently scheduled for sometime this fall.

That launch was originally targeting an April launch, but according to official announcements has been delayed until the fall because final ground testing of its payload, Sierra Space’s Tenacity mini-shuttle, is not complete. It appears that Blue Origin also contributed to that delay, as it is now obvious that its engines were not available as planned in time for that April launch.

This delay also raises questions about Blue Origin’s ability to ramp up BE-4 engine production to meet the needs of ULA’s Vulcan rocket and Blue Origin’s New Glenn rocket. Both have large launch contracts with Amazon to launch its Kuiper constellation, while ULA also has almost as many contracts with the U.S. military. To meet those contracts, Blue Origin will have to produce several hundred BE-4 engines yearly in the very near future. Right now it appears it can only produce about one per year.

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ULA completes last Delta-4 Heavy launch

10:06 am

Delta-4 Heavy on its last launch
Delta-4 Heavy on its last launch

ULA today successfully completed the last Delta-4 launch, the Delta-4 Heavy version — the most powerful — lifting off from Cape Canaveral and placing a National Reconnaissance Office surveillance satellite into orbit.

From this point on ULA will rely on its new Vulcan-Centaur and Atlas-5 rockets, though production of the Atlas-5 has ceased. When the remaining Atlas-5s are flown, the Vulcan-Centaur in its many iterations will become the company’s mainstay rocket. All this might change depending on who buys ULA. If Blue Origin buys the company, the mix will be more complex, as that company is developing its own New Glenn rocket.

This was ULA’s second launch in 2024, so there is no change to the leader board in the 2024 launch race:

36 SpaceX
14 China
5 Russia
4 Rocket Lab

American private enterprise now leads the rest of the world combined 42 to 25, while SpaceX by itself leads the rest of the world, including other American companies, 36 to 31.

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ULA begins stacking Atlas-5 rocket for launching the first manned mission of Starliner

9:26 am

ULA has begun to assemble the Atlas-5 rocket that will hopefully launch Boeing’s Starliner capsule on its first manned mission to ISS, presently targeting a late April lift-off.

The rocket’s main stage was transferred from the nearby Advanced Spaceflight Operations Center to the integration facility Wednesday, Feb. 21, where it will await integration with the rocket’s upper Centaur stage and Starliner. The spacecraft will carry NASA astronauts Suni Williams and Butch Wilmore to the orbiting laboratory for a short stay of about one to two weeks before returning to a landing site in the southwest United States.

The late April date appears to be a slight delay from previous announcements.

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