ULA pinpoints reason a nozzle fell off a Vulcan rocket side booster during last launch

During a press briefing earlier this week, ULA’s CEO Tory Bruno noted that a manufacturing defect was the reason a nozzle fell off one of the two solid-fueled strap-on boosters during the second launch of the company’s new Vulcan rocket.

In a March 12 media roundtable, Tory Bruno, president and chief executive of ULA, said the anomaly was traced to a “manufacturing defect” in one of the internal parts of the nozzle, an insulator. Specific details, he said, remained proprietary. “We have isolated the root cause and made appropriate corrective actions,” he said, which were confirmed in a static-fire test of a motor at a Northrop test site in Utah in February. “So we are back continuing to fabricate hardware and, at least initially, screening for what that root cause was.”

The company however still awaits approval by the Pentagon to begin Vulcan commercial military launches. That delay has forced it to shift its first launch in 2025 from Vulcan to an Atlas-5 launch of Amazon’s first set of operational Kuiper satellites. Bruno also revealed during the press briefing that the company has scaled down the number of launches it hopes to complete in 2025 from 20 to 12, with the reduction caused almost entirely by fewer Vulcan launches.

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ULA & Northrop Grumman complete static fire test of Vulcan strap-on booster

As part of its investigation into the loss of a strap-on booster nozzle during the second launch of ULA’s Vulcan rocket in October 2024, ULA and Northrop Grumman on February 13, 2025 successfully completed a static fire test of another strap-on booster.

The test was also apparently done in order to convince the Space Force to certify Vulcan for military launches. The Pentagon originally required Vulcan to complete two launches before certification, something that second launch achieved despite the loss of the nozzle. It has held off that certification however, insisting on more information into the nozzle loss.

The investigation has scrambled ULA’s planned launch schedule. The company had hoped after the second certification launch to fly two Space Force commercial launches before the end of 2024. Both launches were pushed back into 2025, so much so that ULA has been forced to de-stack a Vulcan rocket so it can instead do an Atlas-5 launch first, carrying the first set of Amazon’s Kuiper satellites.

Whether the results of this static fire test will satisfy the military is at present unknown. No details about the test were revealed, other than the companies were studying the results.

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ULA swapping Vulcan for Atlas-5 for first 2025 launch

ULA has decided to destack the Vulcan rocket it had planned as its first launch in 2025 (launching a military payload) and is now replacing it with one of its remaining Atlas-5 rockets to put the first batch of satellites for Amazon’s Kuiper internet constellation.

It appears the military is not ready to certify this launch after the second Vulcan launch in October 2024 experienced a problem with one of its strap-on boosters. The payload got to its proper orbit, but the loss of that booster’s nozzle appears to be an issue the military remains concerned about.

Rather than wait, ULA decided to switch to the Kuiper launch. The company wants to complete up to 20 launches in 2025, many of which are for Amazon using its last ten or so Atlas-5 rockets. When it can start commercial launches of Vulcan remains somewhat uncertain. The military has indicated it will make a final decision of certification in the spring, and has also said that first operational flight will follow soon after.

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ULA’s CEO outlines a bright 2025 for its Vulcan rocket

In an interview for the website Breaking Defense, ULA’s CEO Tory Bruno outlined his optimistic outlook in 2025 for its Vulcan rocket, despite the loss of a nozzle from a strap-on booster during its second test launch.

The important take-aways:

  • He expects the military to certify the rocket “momentarily”, though this could mean one to several months.
  • The company plans 20 launches in 2025, with 16 Vulcans already in storage.
  • Eventually Bruno expects to be launching 20 to 30 times per year.
  • Blue Origin has so far delivered 12 BE-4 engines, of which four have flown.
  • Blue Origin’s production rate is presently one per week.

The last two items are significant. If this production rate is the fastest Blue Origin can do, it will limit the number of Vulcan and New Glenn launches significantly per year. For example, Vulcan uses two engines per launch. To do 20 launches in 2025 will require 40 engines. Blue Origin however wants to also launch its New Glenn a number of times in 2025, and it uses seven BE-4 engines per launch. A production rate of one per week means that Blue Origin will not be producing enough engines for the number of launches planned for both rockets. Either ULA will have to delay its Vulcan launches awaiting engines, or Blue Origin will have to do the same for its New Glenn.

Of course, it is also possible that Blue Origin will be able to up this production rate with time. It has certainly made progress in this area in the past year, since a year ago it was having trouble producing one engine per month.

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The next two Vulcan launches for the Pentagon slip to 2025

Both the Space Force and ULA have now admitted that the next two Vulcan launches, which both had hoped to launch before the end of this year, have now been delayed until 2025, and that Vulcan remains uncertified as yet by the military for its launches.

The United Launch Alliance’s Vulcan will not be able to conduct two planned national security missions on its launch manifest for this year after delays with certifying the heavy-lift rocket. The comments came hours after a Space Force official cast doubt that the missions could be completed before the end of 2024.

ULA launched its second certification flight in October, roughly a month behind schedule, following a first flight in January that was nearly four years behind schedule. The Space Force is still assessing data from the October launch in partnership with ULA.

The military had said if ULA completed two Vulcan successful launches it would approve Vulcan for these launches. Though the second launch got its payload to its correct orbit, during launch the nozzle on one of its strap-on solid-fueled boosters fell off. Though officials keep saying they expect certification anyway, that certification has not happened. It appears right now that the military won’t do so until the investigation into the problem is completed and a fix is installed.

At the moment the only rocket company that can launch large payloads for the Pentagon is SpaceX. Though that company has not gouged the military in bidding (though it it could) this is not a good situation. The military wants options and redundancy, not simply to save money, but to give it flexibility. It needs ULA and Blue Origin to finally deliver their rockets.

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ULA begins stacking Vulcan for military launch, anticipating Pentagon approval

Though the Space Force is still reviewing the nozzle issue on the second flight of ULA’s Vulcan rocket and has not yet certified the rocket for military operational launches, ULA has begun stacking the next Vulcan for an anticipated military launch of a national security satellite.

On Monday [October 21], ULA shared photos of the 109.2-foot-long (33.3 m) booster being hoisted into the Vertical Integration Facility to begin the stacking process. In the days and possibly weeks to come, the 38.5-foot-long (11.7 m) Centaur 5 upper stage will be added along with four solid rocket boosters and the payload fairings.

It appears that the military has accepted Vulcan for this launch because — despite the nozzle falling off of
a strap-on side booster — the rocket was successful in placing its payload in its precise orbit. The Space Force is simply completing the paperwork required for certification.

No date however has been set, but the company hopes to complete two military Vulcan launches in 2024, so it won’t be that far in the future.

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Space Force awards SpaceX big launch contract

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

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

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

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

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

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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