NASA officials on Wednesday held a media briefing, during which stakeholders revealed that confidence in Starliner’s ability to return the astronauts is waning. According to Ken Bowersox, associate administrator of the agency’s Space Operations Mission Directorate, teams are “getting more serious about evaluating our other options.”

The primary alternative, officials said, is to fly SpaceX’s upcoming Crew-9 mission with two astronauts rather than four, leaving room for Wilmore and Williams to hitch a ride when that mission concludes in February. They estimated that NASA will make a decision by mid-August.

“We could take either path,” Bowersox said.

Boeing and SpaceX representatives were not present on the call, the intention of which, NASA said, was to provide the agency’s perspective on the mission.

On its way up to the ISS, Starliner suffered two main issues that are giving crews pause over how to return the astronauts. A set of helium leaks that emerged on the spacecraft have since stabilized, according to NASA. However, the other issue, which involves five faulty reaction control system (RCS) thrusters on Starliner’s expendable service module, is still being evaluated.

Officials on Wednesday said ground testing of an identical thruster at White Sands Test Facility in New Mexico revealed that the problem is linked to a tiny Teflon seal on an oxidizer poppet, which controls the flow of propellant into the thruster. Teams theorize that the extreme heat the thrusters experienced during Starliner’s rendezvous with the ISS caused the Teflon to expand, inhibiting flow and causing them to fire at weaker-than-expected levels.

According to Steve Stich, who manages NASA’s Commercial Crew program, a July 27 Starliner hot fire test showed that the affected thrusters—with the exception of one, which has been deactivated—are now firing as expected. This has led engineers to hypothesize that the teflon seals contracted and are no longer blocking propellant from reaching the thrusters. Now, the task is to understand how and why.

Teams are working to better understand how those seals might behave during Starliner’s return trip, but there is not yet consensus on whether they are good to go. According to Bowersox and Stich, there is internal disagreement about returning the astronauts on Starliner versus Dragon, which was amplified with the discovery of the faulty teflon seal.

“We heard enough voices [on the program control board] that the decision is not clear,” said Bowersox.

The officials explained that Boeing, which on Friday asserted it has high confidence in Starliner, is viewing risk based on previous missions and flight performance, while NASA wants to understand the root cause of the issue before it has confidence in returning with crew. Ultimately, NASA administrator Bill Nelson will have the final say.

“Reasonable people could have different views on which path we should take,” said Bowersox, who acknowledged that the chance of an uncrewed return has risen in recent weeks. “I don’t think anyone has taken a view that you could prove is wrong or right.”

NASA will have until mid-August to decide whether the Dragon contingency plan should be put into action.

The ISS has two docking modules that are occupied by Starliner and SpaceX’s Crew-8 capsule, meaning Starliner would need to autonomously undock before Crew-9 launches on September 24. Crew-8 would then depart the space station with the crew of NASA’s Expedition 71, and the Crew-9 Dragon would take its place, leaving one docking port open for the next SpaceX cargo mission. Wilmore and Williams would stay for the duration of Crew-9, flying home with the two-person Expedition 72 crew in February.

The problem, though, is that Starliner’s flight software is not currently capable of an autonomous undocking despite having achieved the feat during an uncrewed mission in 2022.

For the CFT, the software was configured for a crewed undocking, as per the mission profile. Now, Boeing and NASA must modify the mission data load to reconfigure the system for an uncrewed undocking, which sources say could take up to one month. NASA said the spacecraft has built-in fault tolerance that would prevent it from colliding with the ISS should its thrusters not perform as expected during that maneuver.

The agency said it has been in daily communication with Wilmore and Williams and that the astronauts are prepared for whatever path it ultimately takes. If they stay along with Crew-9, they will assist personnel with scientific research, including spacewalks. Additional materials, such as spacesuits, would be sent up with the Dragon.

“Butch and Suni are ready to support whatever we need to do,” said Dana Weigel, manager of NASA’s ISS program.

Officials insist that despite the internal conflict around Starliner, the vehicle could still be used to return the astronauts in the case of a contingency on the ISS. In those scenarios, Bowersox said, NASA is willing to tolerate a higher level of risk—one that is jeopardizing teams’ ability to complete the CFT as intended.

The worst-case scenario, according to NASA, would be if the helium leak and thruster issues converge during Starliner’s deorbit burn, the maneuver that will place it back in Earth’s atmosphere. An unlikely combination of technical failures could impact the ability of the RCS thrusters to maintain the capsule’s orbital trajectory, though agency research predicts that it could complete the maneuver even with multiple failures.

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The post NASA: Starliner Astronauts May Not Return Until February appeared first on FLYING Magazine.

NASA and Boeing are in the midst of the inaugural crew flight test (CFT) of Starliner, a semireusable vessel to the ISS under contract for agency service missions as soon as next year. But en route to the orbital laboratory, the spacecraft suffered several anomalies that have led teams to keep it on the ISS for further testing.

A preflight readiness review, during which crews would make a determination on Starliner’s return date, was expected last month but has since been pushed back, with no updates provided since last week.

NASA and Boeing last held a meeting to discuss Starliner’s issues with the media on July 25 and have insisted that the Boeing capsule will return the astronauts to Earth. However, as first reported by Ars Technica and confirmed by FLYING, it appears the space agency is considering enlisting SpaceX’s Dragon.

“NASA is evaluating all options for the return of agency astronauts Butch Wilmore and Suni Williams from the International Space Station as safely as possible,” a NASA spokesperson told FLYING. “No decisions have been made and the agency will continue to provide updates on its planning.”

The statement is a marked shift from the agency’s tone thus far, which has been adamant about Starliner safely returning Wilmore and Williams.

While SpaceX’s Dragon is not mentioned by name, it is the only vehicle in NASA’s ISS Commercial Crew rotation program. Steve Stich, who manages the Commercial Crew program, previously said that there were no discussions between the agency and SpaceX about using Dragon as an alternative. However, NASA in July issued a task award for SpaceX to study flying Dragon with six passengers, rather than the typical four.

In theory, the spacecraft could accommodate the four-person crew of SpaceX’s upcoming Crew-9 mission in addition to Wilmore and Williams. NASA is reportedly also considering flying Crew-9 with two crewmembers, leaving room for the two astronauts on the ISS.

The problem, though, is that Crew-9 on Tuesday was delayed from August 18 to September 24 to give Starliner teams more time to finalize a return plan.

Multiple independent sources also told Ars Technica that Starliner’s onboard flight software is not currently capable of completing an automated undocking from the ISS—despite the capsule completing that maneuver during an uncrewed flight test in 2022—and could take nearly a month to be updated.

If the report is accurate, the software issue would compound Starliner’s existing problems, the most consequential being a set of misfiring thrusters.

Five reaction control system (RCS) thrusters on the spacecraft’s service module fired at lower levels than expected during the trip to the orbital laboratory. The thrusters have been tested on orbit and are now operating at or near expected levels, according to NASA.

But the agency continues to wrap up ground testing at White Sands Test Facility in New Mexico, where an identical thruster is being evaluated. It appears crews do not yet have full confidence in the thrusters’ performance, as evidenced by the delay to the flight readiness review.

NASA continues to tout safety as its highest priority for the CFT, but there are certainly some politics at play.

On July 25, Stich said NASA would like to see Starliner return Wilmore and Williams during the CFT, implying that another crewed test could be required for certification if it doesn’t. The CFT is intended to be the final test flight, but Stich previously acknowledged that certification could take longer than originally expected.

Boeing last week released a statement appearing to publicly pressure NASA, reiterating its confidence in the vessel as evidenced by the extensive testing that has been performed since it docked at the ISS.

Already, Starliner’s inaugural service mission has been delayed from February to August 2025, adding to the almost decade of setbacks the program has suffered. Adding to the headache, Boeing has reportedly spent $1.6B on Starliner so far.

The manufacturer has plenty of incentive to push for Wilmore and Williams’ return on the spacecraft. But at the same time, a failed mission would likely torpedo the program, leaving stakeholders with a difficult decision.

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Boeing’s CST-100 Starliner—a semireusable spacecraft under a multibillion-dollar contract with NASA for Commercial Crew rotation missions to the ISS—underwent a hot fire test on Saturday intended to evaluate the capsule’s reaction control system (RCS) thrusters. The vessel is in the midst of its crewed flight test (CFT), which is intended to be its final mission before NASA certifies it for service.

On its way to the orbital laboratory, five of Starliner’s RCS thrusters failed to perform as expected, which, coupled with a series of helium leaks, has led NASA and Boeing to keep the spacecraft at the ISS for further testing both on the ground and in orbit. The issues are traced to the spacecraft’s service module, which, unlike the semireusable crew module, will be jettisoned and lost at the end of the mission.

Starliner had already undergone one on-orbit hot fire test in June. According to Steve Stich, manager of NASA’s Commercial Crew program, all thrusters, except for one which has been shut down, performed at 80 to 100 percent during that test. Stich in July said the space agency continues to hold that assessment.

However, it appears the test was not satisfactory for NASA and Boeing, which last month began hot fire ground testing at White Sands Test Facility Test Facility in New Mexico. The campaign is using an identical thruster to recreate the cadence of Starliner’s thrusters during its docking with the ISS, which engineers believe is the maneuver that caused the issue.

As part of those evaluations, officials suggested there could be a second hot fire test of Starliner on orbit, which came to fruition Saturday. With Wilmore and Williams inside the spacecraft, teams fired 27 of the service module’s 28 RCS thrusters one at a time.

The test showed that all thrusters are back to preflight levels, firing at 97 to 102 percent of peak thrust according to Boeing. In addition, engineers confirmed that helium leak rates remain stable and that the spacecraft has more than enough fuel for its return trip.

Boeing predicted that a flight test readiness review will take place by the end of this week, following which teams will select a return date. Wilmore and Williams will also participate in two undocking simulations during the week in preparation for their homecoming.

The astronauts in July gave their first Earth-to-orbit update since arriving at the ISS, saying they are in good spirits and have been in contact with their families.

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The post Stuck Boeing Starliner Completes Thruster Testing on Orbit appeared first on FLYING Magazine.

The approval will allow SpaceX to stay on schedule with its Crew-9 mission to rotate astronauts at the International Space Station (ISS), which NASA officials on Friday said is planned for no earlier than August 18.

Falcon 9 was grounded by the FAA following a rare mishap during a July 11 launch of Starlink satellites, its first failure after a streak of more than 300 successful missions.

SpaceX on Thursday shed more light on the incident. The company traced the anomaly to a cracked sense line that created a liquid oxygen leak within the rocket’s second stage engine. This caused ignition fluid to freeze, preventing the engine from performing a burn that would have placed the satellites in a circular orbit.

Despite the issue, SpaceX said, the engine continued operating as intended through both of its planned burns, but all 20 satellites were lost.

The FAA swiftly grounded Falcon 9 as is standard whenever a launch does not go according to plan. SpaceX submitted a mishap report on the night of the anomaly.

Steve Stich, manager of NASA’s Commercial Crew program, said Friday that “SpaceX went above and beyond” in its assessment of the issue, working with NASA to develop a fault tree, review spacecraft telemetry, analyze video, and search for similar issues on other Falcon models.

The company has opted to remove the faulty sense line, which is redundant and not a part of the spacecraft’s safety system, for near-term Falcon 9 launches. It also agreed upon several corrective actions with the FAA that will be detailed in the coming days.

The FAA must still give a final sign-off for Crew-9 to launch, but the blessing to return to flight should allow SpaceX to meet its mission timeline. Stich on Friday said Crew-9 will launch no earlier than August 18 from Launch Complex 39-A at Kennedy Space Center in Florida, with the launch window extending into September.

The mission represents the fourth flight of this particular Falcon. It will launch SpaceX’s Crew Dragon on its 45th mission to the ISS. Once onboard, four crewmembers will spend six months conducting a range of experiments, including studying the physics of neutron stars and the behavior of wildfires on Earth.

The ISS’ two docking ports are occupied by SpaceX’s Crew-8 Dragon capsule and Boeing’s Starliner, the latter of which will need to make way for Crew-9. Complicating matters, however, is the unexpected extension of Starliner’s inaugural crew flight test (CFT), which has left astronauts Butch Wilmore and Suni Williams aboard the orbital laboratory for nearly two months.

Sources told Ars Technica’s Eric Berger that NASA is considering sending Crew-9 to the ISS with only two astronauts, theoretically making room for Wilmore and Williams to hitch a ride home on SpaceX’s Dragon rather than Starliner.

The scenario is one NASA hopes to avoid. Officials stopped short of calling it a requirement for certification but said that returning the astronauts home on Starliner rather than Dragon is “important” to the program’s goals. According to Stich, teams have finished an approximately monthlong test of Starliner’s thrusters and are working toward a flight readiness review, expected toward the end of next week.

However, Stich also said that NASA has officially handed over the Starliner’s first mission—which was double booked for early next year—to SpaceX. The flight, Starliner-1, will be pushed to no earlier than August 2025, while Falcon 9 and Dragon handle the agency’s tenth commercial crew rotation in February. Starliner-1 will again be double booked with SpaceX Crew-11.

Though SpaceX’s Falcon woes haven’t derailed Crew-9, they may shake up NASA’s busy ISS manifest. The agency is working toward an August 3 launch of Northrop Grumman’s Cygnus, followed by an August 13 Roscosmos launch. Crew-9 would be next, followed by SpaceX’s Polaris Dawn mission, originally scheduled for this month.

Beyond that, NASA wants to make a Soyuz ISS crew exchange in September, launch the Europa Clipper probe in October, and facilitate the Axiom-4 private astronaut mission in November.

Given the rapid turnaround following Falcon 9’s rare mishap, Boeing’s Starliner may be a larger culprit than SpaceX in any future delays.

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For the public, those were the first words heard from NASA astronauts Butch Wilmore and Suni Williams—the crew of the space agency’s Boeing Crew Flight Test (CFT)—since they arrived at the orbital laboratory more than one month ago for an intended eight-day stay.

The Earth-to-orbit call between crew and NASA command was live streamed on the agency’s website. The event answered appeals from members of the media, made during a previous press conference, to see the astronauts on camera as concerns with Boeing’s CST-100 Starliner—which brought them to the ISS—continue to linger.

The spacecraft is contending with two key problems: helium leaks and deactivated or underperforming thrusters. The issues are concentrated within the spacecraft’s service module, which aids in maneuvers such as docking and undocking with the ISS.

NASA and Boeing have indicated that Starliner has more than enough helium to make it home but are continuing to assess the root cause of the leaks. During a hot fire test after docking, four out of the five affected thrusters performed as expected. The fifth was deactivated for the remainder of the mission.

Williams and Wilmore recounted their trip to the space station and the moment they realized that Starliner’s thrusters were not firing at full power. They also sang the spacecraft’s praises, with Wilmore even saying he was tempted to award his first perfect rating for its handling performance.

Separately, NASA and Boeing representatives held a press conference to provide the latest on ongoing ground thruster testing at White Sands Test Facility in New Mexico. Officials again did not provide a firm return date for Wilmore and Williams. But Steve Stich, manager of NASA’s Commercial Crew program, estimated that testing could wrap up by the end of the month, after which point teams will iron out a timeline.

Engineers hope to conduct as many evaluations as possible while the semireusable spacecraft, designed to survive 10 missions, is in orbit. Starliner’s service module, the expendable component of the spacecraft, will be jettisoned and lost as it reenters Earth’s atmosphere.

Astronauts Phone Home

Williams and Wilmore on Wednesday made their long-awaited first appearance on camera since arriving at the ISS on June 6, recounting the CFT’s progress so far.

“Launch was spectacular,” Wilmore said, adding that the spacecraft performed “unbelievably well” during operational capability checks.

However, on the second day of their journey to the ISS, the astronauts could tell something was amiss. As Starliner approached the orbital lab, a total of five reaction control system (RCS) thrusters on its service module either turned off or did not fire at intended strength. Williams and Wilmore commandeered the capsule manually for about one hour as teams on the ground assessed the issue.

“From that point on, you could tell that the thrust was degraded,” Wilmore said. “But it was still impressive.”

Even with less-than-optimal performance, the thrusters completed what Wilmore described as a perfect maneuver as they navigated the final 10 meters to dock Starliner with the space station.

According to Williams, the astronauts talk with mission crews once per week to share and analyze the data they’ve collected. She highlighted the capsule’s ability to serve as a “safe haven” in the event of an ISS evacuation—a role it fulfilled last month after a Russian satellite broke up in orbit.

“We are having a great time here on the ISS,” said Williams. “I’m not complaining, Butch isn’t complaining, that we’re here for a couple extra weeks.”

One question NASA and Boeing have received is whether Starliner could bring Williams and Wilmore home right now. Officials insist it could, but only in an emergency situation that would require the ISS to be evacuated. The astronauts were asked about their confidence level in that scenario.

“I feel confident that, if we had to—if there was a problem with the International Space Station—we could get in the spacecraft and undock, talk with our team, and figure out the best way to come home,” said Williams.

She later added, “I have a real good feeling in my heart that the spacecraft will bring us home no problem.”

Wilmore said he and his crewmate “trust the tests we are doing are the right ones we need to do to get us the right answers, to give us the data we need to come back,” adding that they are “absolutely ready” for a return based on current engineering data.

NASA could send a SpaceX Crew Dragon capsule—which has completed all eight ISS Commercial Crew rotation missions to date—to retrieve the astronauts should Starliner’s issues persist. On Wednesday, Stich said the space agency has not yet opened those discussions with SpaceX, though he did not rule out the possibility.

The astronauts also described their view of Hurricane Beryl from space, saying that their families—who live in Texas and were in the storm’s path—are doing well. Wilmore said he is “90 percent sure” he could see the storm forming off the West coast of Africa days before it was named.

The 20-minute call concluded with some zero-gravity backflips by Williams and a big, smiling thumbs-up from Wilmore.

NASA, Boeing Share More Info

Stich and Mark Nappi, vice president and general manager of Boeing’s Commercial Crew program, addressed the media following the astronauts’ remarks.

According to Stich, Starliner will need to undock before mid-August, when SpaceX’s Crew-8 team swaps with the incoming Crew-9. Williams and Wilmore will need to return a few days before the Crew-9 launch window opens. Starliner remains a “go” for return in an emergency scenario, officials said. But they prefer to wait until ground testing is complete before attempting a by-the-books return,

Stich estimated that hot fire testing at White Sands could “optimistically” wrap up by the end of July, though it could be extended. Teams are working toward a nominal return flight readiness review, standard for crew rotation missions, that would give the green light to finish the mission as planned. 

Should more time be needed, NASA is in the process of approving a 45-day extension of the CFT, which is contingent on the health of Starliner’s batteries. According to Stich, those systems have shown no sign of wear and tear.

The goal of the test campaign is to recreate the firing pattern of one of Starliner’s faulty thrusters using an identical thruster—designed for a future mission—on the ground. Hot fire testing began on July 3, but Stich said crews have so far been unable to achieve the temperatures experienced by the thruster in orbit. Engineers believe the unusual firing pattern could be due to excess heat.

Teams will then attempt to predict how the thrusters might behave as Starliner undocks and flies home. Based on their learnings, they could modify the spacecraft’s flight path, deactivate certain thrusters, or fire them at different rates. Williams and Wilmore are capable of piloting Starliner manually if issues arise.

At the same time, Stich said White Sands personnel are evaluating the service module for Starliner’s inaugural crew rotation mission, Starliner-1, scheduled for February. The current service module has contended with a series of helium leaks, for which crews are attempting to uncover the root cause. Starliner-1’s service module won’t be redesigned, but Nappi said future models could incorporate changes based on the testing at White Sands.

The Outlook

Extended ISS stays are not necessarily uncommon, and the space station is designed to accommodate crew for months at a time if needed.

NASA astronaut Frank Rubio, for example, set a U.S. spaceflight record when his planned six-month mission was nearly doubled to 371 consecutive days aboard the orbital laboratory. Unlike Starliner, the Russian Soyuz capsule that ferried Rubio to the ISS was quickly ruled out as an emergency return vehicle, lending credence to the idea that Boeing’s issues are less severe.

However, NASA and Boeing face the added pressure of certification after close to a decade of delays to the Starliner program. In a prior press conference, Stich acknowledged that NASA and Boeing “understand it’s going to take a little bit longer” to certify Starliner than originally planned.

On Wednesday, the Commercial Crew manager said teams will decide between Starliner-1 or SpaceX Dragon’s Crew-10—which are booked for the same February launch window—once the CFT ends and postflight analysis is complete. The longer that takes, he said, the more likely it is that SpaceX will take over the mission.

Nappi agreed with that assessment, citing the need to understand and fix Starliner’s helium leaks as the biggest obstacle to certification.

NASA and Boeing said Wilmore and Williams will make one more Earth-to-orbit call before they depart the ISS, with more details to come.

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The post Boeing Starliner Astronauts Give Earth-to-Orbit Update appeared first on FLYING Magazine.

During a media briefing on Friday, NASA and Boeing representatives said the astronauts’ return to Earth will come after ground testing at the White Sands Test Facility in New Mexico is complete. Teams are working to re-create some of the issues experienced by the reusable spacecraft during its inaugural crewed flight to the orbital laboratory.

According to Steve Stich, manager of NASA’s Commercial Crew program, Starliner was originally deemed safe for a stay as long as 45 days on the ISS. Crews are in the process of extending its battery life, which Stich said will keep the risk level manageable for another 45 days, at least.

However, he conceded that NASA and Boeing “understand it’s going to take a little bit longer” to certify Starliner than previously planned. The spacecraft is scheduled to fly its first service mission, Starliner-1, early next year. Officials said SpaceX’s Crew Dragon, which has completed all eight commercial crew rotation missions to the ISS to date, could take that slot.

“We’re not in any rush to come home,” Stich said Friday. “The risk for the next 45 days is essentially the same as for the first 45 days.”

Added Ken Bowersox, associate administrator of NASA’s Space Operations Mission Directorate: “We have the luxury of time.”

Stich, Bowersox, and Mark Nappi, the manager of Boeing’s commercial crew program,  reiterated that “engineering data suggests” Starliner is safe to return Wilmore and Williams to Earth in the event of an emergency.

Officials also reported that the spacecraft is in “good shape” despite two lingering issues—a set of helium leaks and faulty thrusters.

A total of five helium leaks have sprung up on Starliner’s service module, which makes tiny maneuvers to the spacecraft to assist in docking and keep it in orbit. After testing the helium manifolds earlier this month, NASA found that leak rates had declined. Stich on Friday said those rates have not changed.

The other issue involves the service module’s thrusters, some of which did not fire at full strength en route to the ISS. These were also assessed earlier this month, and Stich said performance on all thrusters is between 80 and 100 percent.

It appears the thrusters are the main factor necessitating a longer mission for Starliner. As soon as Tuesday, engineers will begin testing an identical component at White Sands to re-create the firing pattern of one of the in-orbit thrusters. Officials said the campaign is expected to last several weeks and could be extended.

According to Nappi, teams want to keep Starliner in space for the evaluations because they could inform additional in-orbit tests or a modification of the spacecraft’s undocking procedure. He said crews do not yet understand the issue well enough to fix them permanently and that it would be “irresponsible” not to use additional time to conduct testing. Starliner’s crew module is reusable for up to 10 missions, but the service module will be jettisoned during the CFT.

Nappi said he has been in contact with Wilmore and Williams and that they remain in good spirits, describing Starliner as “pristine and precise.” The astronauts are able to communicate with their families daily and according to officials are not “stranded.”

On Wednesday, Starliner got another real-life test when an in-orbit satellite breakup created a debris field that hurtled toward the ISS. Wilmore and Williams tested the spacecraft’s ability to act as a “safe haven” in the case of a contingency on the space station, getting inside, powering it up, and sealing the hatch. They remained inside for an hour and according to officials were prepared to initiate an undocking if necessary.

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The post Starliner Astronauts Prepare for Extended ISS Stay appeared first on FLYING Magazine.

Wilmore and Williams began their sojourn to the ISS on June 5 with plans for an eight-day stay but will now spend a minimum of three weeks aboard the orbital laboratory.

Partners NASA and Boeing—under contract for six Starliner Commercial Crew missions following the completion of the CFT and the vehicle’s certification—had previously targeted a return date of Saturday, doubling the length of the astronauts’ mission. On Tuesday, however, they decided to further delay a return to allow teams to collect data from Starliner’s service module.

The service module, which makes small maneuvers to align the capsule such as when orbiting or docking, is an expendable component that is jettisoned before the spacecraft reenters the atmosphere. NASA and Boeing hope to study it further in order to assess issues that have arisen during the mission. Their findings will inform any modifications required before the capsule can be certified to enter NASA’s rotation.

NASA Commercial Crew program manager Steve Stich, ISS program manager Dana Wiegel, Johnson Space Center flight director Mike Lammers, and Boeing Commercial Crew program manager and vice president Mark Nappi addressed those problems Tuesday.

Starliner is contending with three main issues. The most significant is a series of helium leaks traced to the seals between the service module’s thrusters and manifold, of which crews have identified five. The first leak was discovered during prelaunch preparations, two were uncovered on the way to the ISS, and two more were identified after docking.

Another complication, which teams on Tuesday theorized may be connected to the helium leaks, involves the service module’s aft reaction control system (RCS) thrusters. Five of these engines failed to fire during the final phase of the spacecraft’s rendezvous with the ISS. Each phase of the remainder of the CFT requires a different number and arrangement of RCS thrusters.

The last problem stems from a faulty oxidizer isolation valve, which has been closed for the remainder of the mission. All other valves are functioning normally, NASA said.

According to Wiegel, the ISS can hold Wilmore and Williams indefinitely as NASA and Boeing prepare Starliner for undocking. Nappi said 77 of 87 CFT flight test objectives have already been completed, with the remaining few taking place during the trip back to Earth. He described the astronauts’ extended stay as an “opportunity” and a “privilege” to study Starliner further on orbit, which is considered an ideal test environment.

Over the past week and a half, Starliner teams have been busy gathering flight data on thruster firing, docking, and other maneuvers, as well as performing testing and analysis on the ground.

During a hot fire test over the weekend, one of the five RCS thrusters displayed what Stich described as “a strange signature where we’re getting almost no thrust out of that [engine].” Crews have opted to power down the thruster for the remainder of the mission. Three other thrusters functioned as expected.

On Starliner’s first visit to the ISS in 2022, a similar issue occurred where two RCS thrusters failed. Stich theorized that heat may be causing propellant in the engines’ chambers to vaporize.

The hot fire test also reflected a promising outlook for the helium manifold problem: “I would say every single manifold that we looked at [following testing], we saw the leak rates going down,” said Stich.

Starliner requires about seven hours’ worth of helium to undock from the ISS, perform a deorbit burn, and touch down on Earth, representing the final steps of the CFT. On Tuesday, teams estimated that the spacecraft will have at least 70 hours of margin.

According to Stich, three helium leaks, described as larger than the rest, tend to reach their highest rate when the service module’s RCS thrusters are firing, leading he and NASA to believe there may be a link between the two problems. As noted earlier, two leaks were identified after Starliner docked to the ISS, which Stich said placed an unexpected amount of demand on the thrusters.

Stich added that the two leaks discovered en route to the orbital laboratory stabilized while Wilmore and Williams took their designated sleep, suggesting there could be some correlation between thruster activity and leak rate. He theorized that the seals on the service module’s helium manifolds could be getting worn down due to extreme heat, for example.

NASA and Boeing representatives said Wilmore and Williams remain in good spirits aboard the ISS. The astronauts are using their extended stay to perform additional tests and equipment checkouts, including a demonstration of Starliner’s use as a safe haven in the case of a contingency aboard the space station. Stich likened the scenario to seeking refuge in a storm cellar during a tornado.

Crews throughout the week will continue to conduct evaluations of Starliner on orbit and on the ground, including simulations of the mission’s final phase. If all goes according to plan, Starliner, carrying Wilmore and Williams, will undock from the ISS on June 25 and land at White Sands Space Harbor the following morning at 4:51 a.m. EDT. Additional landing opportunities are available every four days, with the next being June 30.

The CFT is intended to be Starliner’s final test flight before the vehicle is certified by NASA for service missions. On Tuesday, representatives did not dismiss the possibility of a delay in certification to address the spacecraft’s frequent issues. The vehicle’s first operational mission, Starliner-1, is scheduled for 2025.

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The post Boeing Starliner, Crew Will Return to Earth No Earlier Than June 26 appeared first on FLYING Magazine.

On Wednesday morning, the autonomous, semireusable space capsule—intended for 10 service missions to the International Space Station (ISS) under a multibillion contract between the aerospace manufacturer and NASA—finally lifted off with humans for the first time.

The long-delayed mission, called the Boeing Starliner Crew Flight Test (CFT), will take NASA astronauts Butch Wilmore and Suni Williams to the orbital laboratory, where they will conduct an array of tests and evaluations of the spacecraft, its systems, and equipment.

The CFT is expected to be Starliner’s final flight test, demonstrating its capabilities with astronauts on board before NASA moves to certify it for Commercial Crew rotation missions to the ISS. The first of these, Starliner-1, could take place as early as next year.

An initial CFT launch attempt on May 6 was scrubbed, and the mission was postponed several times before finally taking flight. But Wilmore and Williams are now well on their way to the space station, where they are expected to dock Thursday at 12:15 p.m. EDT.

We Have Liftoff

Starliner lifted off from the pad at Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida on Wednesday at 10:52 a.m. EDT as teams had planned.

Carrying the capsule into orbit was United Launch Alliance’s (ULA) Atlas V rocket, which is making its 100th flight. Atlas V, when stacked together with Starliner, stands over 170 feet tall and generated some 1.6 million pounds of thrust at liftoff.

The liftoff represented the first time humans have hitched a ride on either Starliner or Atlas V. Williams became the first woman to fly on the maiden voyage of a crewed spacecraft.

After achieving Max Q—the moment the rocket faces the greatest amount of pressure as it climbs through the atmosphere—Starliner successfully separated from Atlas V at suborbit, just under 15 minutes into the mission. From this point on, the astronauts will be on their own.

About half an hour into the mission, Starliner executed a successful insertion burn to place it in stable orbit, from which the capsule will embark on an approximately 24-hour journey to the ISS. The spacecraft will dock with the orbital laboratory’s Harmony module Thursday afternoon, and Williams and Wilmore will disembark to join the crew of NASA’s Expedition 71 for a weeklong stay.

Setting the Stage

Throughout the CFT, the astronauts will work to prepare Starliner for certification.

The performance of equipment such as suits and seats was assessed during prelaunch and ascent. As Starliner rendezvous with the space station, the crew will conduct further testing of life support equipment, manual and automated navigation systems, and thruster performance in the scenario of a manual abort. While capable of flying on its own, the capsule can be commanded manually, and crews have failsafes at their disposal at different points in the flight path.

After assessing Starliner’s autonomous docking capabilities and the opening and closing of its hatch, the astronauts will configure the spacecraft for its stay and move emergency equipment into the ISS. Once they are settled, teams will perform checks of displays, cargo systems, and the vehicle itself.

Williams and Wilmore will also try to prove that the capsule could serve as a “safe haven” in the event of depressurization, fire, or collision with debris impacting the orbital laboratory.

On their return trip, the astronauts will briefly test out Starliner’s manual piloting capabilities. As it approaches Earth’s atmosphere, the capsule will slow from its orbital velocity of 17,500 mph and touch down in one of four locations in the Western U.S., using a combination of parachutes and airbags.

A Calculated Risk

If all goes according to plan, Starliner could launch on its first Commercial Crew rotation mission for NASA in the first half of next year. However, the space agency, Boeing, and ULA are taking a calculated risk with the mission.

A helium leak traced to one of the 28 reaction control system thrusters on Starliner’s service module—which helps maneuver the capsule while in orbit—is responsible for a few of the spacecraft’s recent setbacks. NASA describes the leak as small and stable.

But in a scenario Steve Stich, who manages the Commercial Crew program, described as “a pretty diabolical case, where you would lose two helium manifolds in two separate [thrusters]” that are next to one another, Starliner could be unable to perform a deorbit burn. That’s the maneuver that allows it to slow down from orbital speeds as it reenters the atmosphere.

NASA estimated the likelihood of this occurring at 0.77 percent. As a contingency, it and Boeing developed a modified deorbit burn procedure which they say has been tested in a simulator by Williams and Wilmore.

What It Means

There’s a lot riding on the Starliner CFT’s success.

For Boeing, which rakes in billions every quarter, the more important impact may be reputational rather than financial. The company has come under fire in recent months for its internal safety processes, and successfully flying two humans to the ISS and back could help ease the pressure.

For NASA, Starliner may be instrumental in achieving the agency’s goals.

To date, all eight Commercial Crew rotation missions have been flown by SpaceX’s Crew Dragon, which like Starliner is a reusable capsule for up to seven passengers. SpaceX signed its own multibillion-dollar contract with the space agency at the same time as Boeing and has since extended it multiple times, without failing to complete a mission.

But NASA wants an alternative to Dragon in the case of a contingency, such as the one that stranded astronaut Frank Rubio on the ISS for nearly a year—and helped him set a U.S. spaceflight record in the process. The space agency made sure to commemorate Rubio’s achievement, but it wants to avoid a similar situation recurring. By keeping two reusable spacecraft in its fleet, it could have one ready to retrieve a crew in case the other fails.

Should Starliner enter NASA’s Commercial Crew rotation, it will alternate six-month missions to the ISS with Dragon.

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The mission, which has faced a series of setbacks since an initial launch attempt was scrubbed on May 6, is now targeted for 10:52 a.m. EDT on Wednesday, with a backup launch window available Thursday.

The Starliner CFT is intended to be the spacecraft’s final test flight before NASA moves to certify it for service missions to the ISS, the first of which could take place next year. To date, all eight Commercial Crew rotation missions to the orbital laboratory have been flown by SpaceX’s Crew Dragon. 

The company signed its own multibillion-dollar contract with the space agency at the same time as Boeing but has already cemented itself as an invaluable partner. The same cannot be said for the aerospace giant, which has flown Starliner to the ISS just once.

CFT launch attempts have been delayed or scrubbed due to a litany of issues. First, it was a faulty pressure regulation valve on United Launch Alliance’s (ULA) Atlas V launch vehicle, which will carry Starliner into orbit. Then, crews discovered a small helium leak on Starliner itself, involving one of the 28 reaction control system thrusters on its service module. These small engines use helium to make minor maneuvers and keep Starliner in orbit.

NASA and Boeing have since described the leak as stable but have opted not to repair it, which would require Starliner to be unstacked from Atlas V and could take months. However, in investigating the root cause of the leak, crews discovered what the space agency described as a “design vulnerability” in the capsule’s propulsion system.

In a scenario NASA estimates has a likelihood of about 0.77 percent, the original leak could combine with an adjacent leak to prevent Starliner from performing a deorbit burn. That’s the maneuver that returns a spacecraft to Earth’s atmosphere following its mission.

All of this work identifying and assessing risk pushed the CFT back to Saturday. But yet another problem forced a cancellation of the launch just a few minutes before takeoff—and made a second go-around on Sunday infeasible.

According to the Starliner team, the issue is again on ULA’s side of things.

During the countdown, ground support equipment on the pad at Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida experienced issues, which crews traced to a power supply unit on one of three chassis on Atlas V’s Centaur upper stage. The power supply unit indirectly powers Centaur’s topping valves during the launch sequence, and all three chassis must be running in order for the countdown to be completed.

According to Tory Bruno, CEO of ULA, the chassis with the faulty power unit was quickly replaced. The new equipment has been retested and was functioning normally as of Sunday. NASA and Boeing added that they did not observe any physical damage to Starliner or Atlas V, and crews will perform a “full failure analysis” to determine what went wrong.

NASA astronauts Butch Wilmore and Suni Williams, Starliner’s first human passengers, remain in quarantine at Kennedy Space Center. If all goes according to plan, Wilmore and Williams will dock with the ISS later this week. There, they will spend about one week performing tests of Starliner’s systems as NASA prepares for the program’s next step: certification.

After that, Starliner would begin alternating six-month Commercial Crew rotation missions with SpaceX’s Dragon.

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NASA and Boeing on Wednesday announced that the Starliner Crewed Flight Test (CFT), intended to be the spacecraft’s final dress rehearsal before the agency certifies it for service missions, is a “go” to proceed for 12:25 p.m. EDT on Saturday, June 1.

However, Starliner engineers during a press conference last week said that a design flaw with the spacecraft’s propulsion system gives the capsule a 0.77 percent chance of being unable to perform a deorbit burn after it returns from the ISS. A deorbit burn, in which the vehicle reverses direction and fires its orbital maneuvering engines to slow itself, is used to maneuver a spacecraft back into Earth’s atmosphere.

NASA, Boeing, and launch provider United Launch Alliance, a joint venture between Boeing and Lockheed Martin, are taking a calculated risk with the launch attempt following years of delays to the Starliner program. The setbacks have resulted from a combination of issues involving the spacecraft’s software, propulsion system, and parachutes.

Boeing and rival SpaceX each have multibillion-dollar contracts with the space agency to provide crew rotation services. But all eight missions to the ISS to date have been flown using SpaceX’s Crew Dragon, which like Starliner is a reusable capsule designed to accommodate up to seven passengers.

Starliner in 2019 and 2022 attempted two uncrewed test flights to the ISS, the first aborted and the second successful.

The capsule’s first crewed mission has been delayed a number of times since an initial launch attempt scheduled for May 6 was scrubbed due to an issue with ULA’s Atlas V launch vehicle. Following that setback, engineers discovered a small helium leak on the Starliner capsule itself, tracing it to one of 28 reaction control system thrusters on the spacecraft’s service module.

“This is a high-pressure system, and helium is a very small, tiny molecule, and it tends to leak,” said Steve Stich, manager of NASA’s Commercial Crew program, last week. “This particular leak, I don’t think it implicates the design of the seal or the flange. It’s just maybe a defective part.”

Rather than replace the faulty valve, which would involve removing Starliner from the Atlas V rocket and could take several months, crews decided to try and better understand the flaw.

According to Stich, Starliner could actually weather a complete rupture in the valve’s seal, even if additional helium leaks spring up elsewhere.

“We could handle this particular leak if that leak rate were to grow even up to 100 times,” he said.

The leak is now described as stable, and Stich noted that SpaceX’s Dragon has also encountered leaks, which did not impact operations. But in the course of investigating the issue, teams uncovered yet another problem.

“We found a design vulnerability…in the [propulsion] system as we analyzed this particular helium leak, where for certain failure cases that are very remote, we didn’t have the capability to execute the deorbit burn with redundancy,” said Stich.

In what Stich described as “a pretty diabolical case where you would lose two helium manifolds in two separate doghouses, and then they have to be next to each other”—referring to the aforementioned 0.77 percent figure—Starliner could be unable to perform a deorbit burn. Engineers said they have come up with a contingency plan that has already been tested by NASA astronauts Suni Williams and Butch Wilmore in a Starliner simulator.

“We have multiple redundancies in our system,” Mark Nappi, vice president of Boeing and program manager for Starliner, said last week. “We have a case here that’s extremely remote that we missed. And if there are more out there, they’re going to be in that same category of extremely remote.”

Though the issue hasn’t entirely gone away, Starliner teams appear committed to a launch on Saturday.

NASA, Boeing, and ULA on Wednesday completed a Delta-Agency Flight Test Readiness Review, determining that all Starliner systems, facilities, and teams are ready for launch. On Thursday, crews rolled Atlas V and Starliner back to the pad at Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida, further signaling their intent to move forward with the attempt.

NASA will provide live coverage of the mission on its website, app, and YouTube channel. If all goes according to plan, Starliner, carrying Wilmore and Williams, will dock to the ISS’s Harmony module Sunday afternoon. The astronauts would then spend about one week on the orbital laboratory, where they will test the capsule’s systems in order to advance the certification process.

NASA hopes to get Starliner into its Commercial Crew rotation with the Starliner-1 service mission, scheduled for no earlier than 2025. After that, it would alternate six-month missions to the ISS with SpaceX’s Dragon.

U.S. Space Force meteorologists on Friday said there is a 90 percent chance that weather conditions will meet the criteria for a safe launch. Should the attempt be scrubbed again, backup launch windows are scheduled for Sunday, June 2, Wednesday, June 5, and Thursday, June 6.

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