Orbital ATK Antares rocket hardware fills the Horizontal Integration Facility from end-to-end at NASA’s Wallops Flight Facility for upcoming ‘Return to Flight’ missions in 2016 from Virginia launch base. Credit: Ken Kremer/kenkremer.com
NASA WALLOPS FLIGHT FACILITY, VA – Assembly and testing of a significantly upgraded version of Orbital ATK’s commercially developed Antares rocket has kicked into high gear and is on target for rebirth – as the clock ticks down towards its ‘Return to Flight’ by approximately mid-2016 from a launch pad at the Mid-Atlantic Regional Spaceport (MARS) in Virginia, company managers told Universe Today during a recent up close media visit to see the actual flight hardware.
SpaceX Falcon 9 rocket with SES-8 communications satellite awaits launch from Pad 40 at Cape Canaveral, FL, file photo. Credit: Ken Kremer/kenkremer.com
SpaceX Falcon 9 rocket after successful static hot-fire test on June 13, 2014 on Pad 40 at Cape Canaveral, FL. Launch is slated for Friday, June 20, 2014 on ORBCOMM OG2 mission with six OG2 satellites. Credit: Ken Kremer/kenkremer.comSpaceX announced today (Dec. 10) that the aerospace firm is now targeting Dec. 19 as the target date for the ‘Return to Flight’ of their Falcon 9 rocket, and comes approximately six months after their last launch in late June 2015 ended suddenly in a catastrophic mid-air calamity resulting in total destruction of the rocket carrying out a critical cargo mission for NASA to the International Space Station (ISS).
The Falcon 9 ‘Return to Flight’ launch attempt from Cape Canaveral, Florida was confirmed by SpaceX CEO and chief designer Elon Musk via twitter this morning.
@OrbitalATK’s #Cygnus spacecraft is moving toward its capture point at the International Space Station as astronaut maneuver the Canadian-built robotic arm to reach out for dramatic vehicle grappling on Dec. 9, 2015. Credit: NASA TV
@OrbitalATK’s #Cygnus spacecraft is moving toward its capture point at the International Space Station as astronauts maneuver the Canadian-built robotic arm to reach out for dramatic vehicle grappling on Dec. 9, 2015. Credit: NASA TV
Story/photos updated
The commercial Cygnus cargo spaceship, loaded with over three tons of critically needed supplies and research experiments, successfully rendezvoused and docked with the International Space Station (ISS) this morning (Dec. 9) after blazing to orbit on Sunday, Dec. 6, and thereby successfully resumed the American resupply chain to orbit – just in time for Christmas in Space!
The Orbital ATK Cygnus CRS-4 resupply vessel arrived in the vicinity of the massive orbiting outpost around 530 a.m. EST today with pinpoint accuracy after precisely firing its maneuvering thrusters to home in on the complex during a two day orbital chase.
First enhanced Orbital ATK Cygnus commercial cargo ship is fully assembled and being processed for blastoff to the ISS on Dec. 3, 2015 on an ULA Atlas V rocket. This view shows the Cygnus, named the SS Deke Slayton II, and twin payload enclosure fairings inside the Kennedy Space Center clean room. Credit: Ken Kremer/kenkremer.com
First enhanced Orbital ATK Cygnus commercial cargo ship is fully assembled and being processed for blastoff to the ISS on Dec. 3, 2015 on a ULA Atlas V rocket. This view shows the Cygnus, named the SS Deke Slayton II, and twin payload enclosure fairings inside the Kennedy Space Center clean room. Credit: Ken Kremer/kenkremer.com
KENNEDY SPACE CENTER, FL – The largest and most advanced version of the privately developed Cygnus cargo freighter ever built by Orbital ATK is fueled, loaded and ready to go to orbit – signifying a critical turning point towards resuming American commercial cargo launches to the space station for NASA that are critical to keep it functioning.
The enhanced and fully assembled commercial Cygnus was unveiled to the media, including Universe Today, during an exclusive tour inside the clean room facility on Friday, Nov. 13, where it is undergoing final prelaunch processing at the Kennedy Space Center (KSC).
Orbital ATK Cygnus cargo spacecraft being processed at the Kennedy Space Center for upcoming unmanned cargo launch to the International Space Station (ISS) on Dec. 3, 2015. Cygnus will ferry more than 7,000 pounds of supplies, equipment and experiments to the ISS. Orbital ATK is vying for NASA’s new Commercial Resupply Services (CRS) contract to supply the ISS through 2024. Credit: NASA
Or will a trio of other American aerospace competitors vying for the new government contracts somehow break through? That’s the multi Billion dollar question since the cargo awards are potentially valued at 3 to 4 Billion dollars or more each.
Well despite widespread expectations that the winners of NASA’s Commercial Resupply Services (CRS) 2 contract for the orbiting outpost would be announced by week’s end, nearly everyone involved will have to wait a few more months while agency officials again postponed a decision in order to ponder the long term implications of “a complex procurement.”
NASA says it needs more time to “assess proposals” and determine which of five private companies will be awarded the governments CRS 2 contracts for the ISS resupply missions.
Although NASA had planned to award contracts to at least two winners on Thursday, Nov. 5, the agency just announced another significant delay for the CRS 2 contract via its procurement website because the decision is “complex.”
“The anticipated CRS2 award is now no later than January 30, 2016 to allow additional time for the Government to assess proposals,” NASA announced on its procurement website.
“CRS2 is a complex procurement.
This new delay follows several earlier postponements already announced this past year.
The two companies currently holding Commercial Resupply Services (CRS) contracts from NASA, namely SpaceX and Orbital ATK, are dueling with new bids from Boeing, Sierra Nevada Corp. (SNC) and Lockheed Martin.
SpaceX Dragon berthing at ISS on March 3, 2013. Credit: NASA
Altogether, those five companies are known to have submitted bids for the CRS-2 procurement by the due date of March 21, 2014. Awards were expected in June 2015 but the timing was repeatedly revised.
Each company was originally expected to deliver 20,000 kilograms (44,000 pounds) of research experiments, crew provisions, spare parts and hardware spread out over multiple cargo delivery flights to the ISS under the initial CRS contract.
The SpaceX Falcon 9 rocket and Dragon cargo spaceship dazzled in the moments after liftoff from Cape Canaveral, Florida, on June 28, 2015 but were soon doomed to a sudden catastrophic destruction barely two minutes later in the inset photo (left). Composite image includes up close launch photo taken from pad camera set at Space Launch Complex 40 at Cape Canaveral and mid-air explosion photo taken from the roof of the Vehicle Assembly Building (VAB) at NASA’s Kennedy Space Center, Florida as rocket was streaking to the International Space Station (ISS) on CRS-7 cargo resupply mission. Credit: Ken Kremer/kenkremer.com
So NASA truly has a lot on the line while considering CRS 2 and postponing a decision may be wise until after both firms successfully complete their upcoming ‘Return to Flight’ missions – now scheduled for Dec. 3 by Orbital ATK and early January 2016 for SpaceX.
Orbital Sciences Antares rocket explodes moments after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014, at 6:22 p.m. Credit: Ken Kremer – kenkremer.com
“The anticipated award date has been revised to no later than January 30, 2016 to allow time to complete a thorough proposal evaluation and selection,” says NASA.
When asked for a comment and explanation on the decisions and delay, a NASA spokesperson responded to me as follows:
“This is all we’ll be able to say, for right now.”
“Since the agency is in the process of evaluating proposals, we are in a procurement communications blackout. For that reason, NASA cannot answer.”
However, Boeing has been told by NASA that they are out of the running for CRS 2. Earlier reports indicated that Lockheed Martin is also out of the competition.
But there is still plenty of really good news for Boeing since they were already awarded a commercial crew contract in September 2014 to develop the Starliner space taxi to launch astronauts to the ISS.
The first Boeing CST-100 Starliner capsule is already being manufactured at the Kennedy Space Center, as I detailed earlier on site – here.
For the CRS 2 contract, Boeing submitted a bid to convert Starliner into an unmanned cargo freighter.
Meanwhile Sierra Nevada Corp told Universe Today that their Dream Chaser space plane “remains in contention.”
Dream Chaser is a winged mini shuttle that lost out in NASA commercial crew program competition. SNC submitted a proposal involving an unmanned version of Dream Chaser for the CRS 2 cargo competition building on what they already developed.
“SNC received notification that NASA has delayed the award decision related to Commercial Resupply Services 2 to no later than January 30, 2016,” SNC spokesperson Krystal Scordo told Universe Today.
“SNC remains part of the competitive range. We are proud of our Dream Chaser® Program team and are pleased to remain in contention for this important work in space.”
Unmanned version of Sierra Nevada Corporation (SNC) Dream Chaser space plane proposal for NASA cargo resupply contract docks at the International Space Station. Credit: Sierra Nevada Corporation
Neither SpaceX or Orbital will comment about the details of their CRS 2 procurement proposals to Universe Today beyond stating to me that they submitted bids and await NASA’s decision.
The CRS 2 contract is a follow on to the original CRS contract which was to run through at least 2016.
In the meantime, NASA opted to extend the original CRS contract to around 2018 by granting additional interim cargo flights to both SpaceX and Orbital under terms allowed by the contract.
SpaceX was granted five additional Dragon flights and Orbital ATK was given three additional Cygnus flights, for a total of 10 Cygnus resupply missions through about 2018.
The CRS-2 contract is valued at between $1.0 Billion and $1.4 Billion per year and NASA requires this service from approximately 2018 through 2024 according to the RFI.
NASA expects delivery of 14,250 to 16,750 kilograms per year of pressurized cargo as well as 1,500 to 4,000 kg per year of unpressurized cargo and return or disposal of up to 14,250 to 16,750 kg per year of pressurized cargo under CRS 2.
Watch for my onsite reports from the Kennedy Space Center press site for the Orbital Atlas OA-4 cargo liftoff on Dec. 3.
“We are anxious to get flying again not only for our own sake, but really for NASA and the crew!” Frank DeMauro, Orbital ATK Vice President for Human Spaceflight Systems Programs, said in an interview with Universe Today.
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
Base of Orbital Sciences Antares rocket explodes moments after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014, at 6:22 p.m. Credit: Ken Kremer – kenkremer.com
Base of Orbital Sciences Antares rocket explodes moments after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014, at 6:22 p.m. Credit: Ken Kremer – kenkremer.com
One year after the catastrophic launch failure of Orbital ATK’s private Antares rocket seconds after liftoff with the Cygnus cargo freighter bound for the International Space Station (ISS), the firm is well on the way towards revamping the booster with modern new engines and implementing a ‘Return or Flight’ by approximately mid-2016, company officials told Universe Today. Antares is on the comeback trail.
Some 15 seconds after blastoff of the firms Antares/Cygnus rocket on October 28, 2014 on the Orb-3 resupply mission for NASA to the space station, the flight rapidly devolved into total disaster when one of the rockets first stage AJ26 engines suddenly blew up without warning after liftoff from NASA Wallops Island facility along the Eastern shore of Virginia at 6:22 p.m. ET.
Cygnus service module built by Orbital ATK in their Dulles, Virginia cleanroom is shown here with unfurled Ultraflex solar panels that will fly for the first time with mated pressurized module on the OA-4 ISS resupply mission on ULA Atlas V rocket on Dec. 3, 2015 from Cape Canaveral, Florida. Credit: Orbital ATK
Cygnus service module built by Orbital ATK in their Dulles, Virginia cleanroom is shown here with unfurled UltraFlex solar panels that will fly for the first time with mated pressurized module on the OA-4 ISS resupply mission on ULA Atlas V rocket on Dec. 3, 2015 from Cape Canaveral, Florida. Credit: Orbital ATK
See OA-4 mission patch and hardware photos below
The biggest and heaviest Cygnus commercial cargo craft ever built by Orbital ATK is coming together at the Kennedy Space Center as the launch pace picks up steam for its critical ‘Return to Flight’ resupply mission to the space station for NASA. Cygnus is on target for an early December blastoff from Florida and the Orbital ATK team is “anxious to get flying again.”
Two RD-181 integrated with the Orbital ATK Antares first stage air frame at the Wallops Island, Virginia Horizontal Integration Facility (HIF). Return to flight launch is expected sometime during Spring 2016. Credit: NASA/ Terry Zaperach
“We are on track for the next Antares launch in early 2016,” said David Thompson, President and Chief Executive Officer of Orbital ATK in a progress update.
Resuming Antares launches is a key part of the company’s multipronged effort to fulfil their delivery commitments to NASA under the Commercial Resupply Services (CRS) contract.
“The focus all along has been to do everything we can to fulfill our commitments to delivering cargo to the space station for NASA,” Thompson stated.
“After the Antares launch failure last October … our team has been sharply focused on fulfilling that commitment.”
Pre-launch seaside panorama of Orbital Sciences Corporation Antares rocket at the NASA’s Wallops Flight Facility launch pad on Oct 26 – 2 days before the Orb-3 launch failure on Oct 28, 2014. Credit: Ken Kremer – kenkremer.com
The key milestone was to successfully re-engine Antares with a new type of first stage engine that completely eliminates use of the original AJ26 engines that were refurbished 40 year leftovers – the NK-33 from Russia’s abandoned manned moon landing program.
After the launch failure, Orbital managers decided to ditch the trouble plagued AJ-26 and “re-engineered” the vehicle with the new RD-181 Russian-built engines that were derived from the RD-191.
Soviet era NK-33 engines refurbished as the AJ26 exactly like pictured here probably caused Antares’ rocket failure on Oct. 28, 2014. Orbital Sciences technicians at work on two AJ26 first stage engines at the base of an Antares rocket during exclusive visit by Ken Kremer/Universe Today at NASA Wallaps. These engines powered the successful Antares liftoff on Jan. 9, 2014 at NASA Wallops, Virginia bound for the ISS. Credit: Ken Kremer – kenkremer.com
Orbital ATK holds a Commercial Resupply Services (CRS) contract from NASA worth $1.9 Billion to deliver 20,000 kilograms of research experiments, crew provisions, spare parts and hardware spread out over eight Cygnus cargo delivery flights to the ISS.
NASA has recently supplemented the CRS contract with three additional Cygnus resupply deliveries in 2017 and 2018.
However, the Cygnus missions were put on hold when the third operational Antares/Cygnus flight was destroyed in a raging inferno about 15 seconds after liftoff on the Orb-3 mission from launch pad 0A at NASA’s Wallops Flight Facility on Virginia’s eastern shore.
Until Antares flights can safely resume, Orbital ATK has contracted with rocket maker United Launch Alliance (ULA) to launch a Cygnus cargo freighter atop an Atlas V rocket for the first time, in early December – as I reported here.
The Antares rocket is being upgraded with the new RD-181 main engines powering the modified first stage core structure that replace the troublesome AJ26 engines whose failure caused the Antares Orb-3 launch explosion on Oct. 28, 2014.
Orbital Sciences Antares rocket explodes moments after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014, at 6:22 p.m. Credit: Ken Kremer – kenkremer.com
“We are making excellent progress in resuming our cargo delivery service to the International Space Station for NASA under the Commercial Resupply Services (CRS) contract,” said company officials.
Orbital ATK engineering teams have been working diligently on “integrating and testing the new RD-181 main engines.”
After engineers finished acceptance testing and certification of the RD-181, the first dual engine set was shipped to Orbital’s Wallops Island integration facility. They arrived in mid-July. A second set is due to arrive in the fall.
“The RD-181 engine provides extra thrust and higher specific impulse, significantly increasing the payload capacity of the Antares rocket. This state-of-the-art propulsion system is a direct adaptation of the RD-191 engine, which completed an extensive qualification and certification program in 2013, accumulating more than 37,000 seconds of total run time,” said Scott Lehr, President of Orbital ATK’s Flight Systems Group, in a statement.
Engineers and technicians have now “integrated the two RD-181 engines with a newly designed and built thrust frame adapter and modified first stage airframe.”
Then they will add new propellant feed lines and first stage avionics systems.
Then comes the moment of truth. A “hot fire” test on the launch pad will be conducted by either the end of 2015 or early 2016 “to verify the vehicle’s operational performance and compatibility of the MARS launch complex.”
“Significant progress has been made in the manufacture and test of the modified hardware components, avionics and software needed to support the new engines,” said Mike Pinkston, Vice President and General Manager of Orbital ATK’s Antares Program.
“We are solidly on track to resume flying Antares in 2016.”
Antares rocket raised at NASA Wallops launch pad 0A bound for the ISS on Sept 18, 2013. Credit: Ken Kremer (kenkremer.com)
Simultaneously, teams have been working hard to repair the Wallops launch pad which was damaged when the doomed Antares plummeted back to Earth and exploded in a hellish inferno witnessed by thousands of spectators and media including myself.
Repairs are expected to be completed by early 2016 to support a launch tentatively planned for as soon as March 2016.
SpaceX, NASA’s other commercial cargo company under contract to ship supplies to the ISS also suffered a launch failure of with their Falcon 9/Dragon cargo delivery rocket on June 28, 2015.
NASA is working with both forms to restart the critical ISS resupply train as soon as can safely be accomplished.
Be sure to read Ken’s earlier eyewitness reports about last October’s Antares failure at NASA Wallops and ongoing reporting about Orbital ATK’s recovery efforts – all here at Universe Today.
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
Learn more about Orbital ATK, SpaceX, Boeing, ULA, Space Taxis, Mars rovers, Orion, SLS, Antares, NASA missions and more at Ken’s upcoming outreach events:
Aug 29-31: “MUOS-4 launch, Orion, Commercial crew, Curiosity explores Mars, Antares and more,” Kennedy Space Center Quality Inn, Titusville, FL, evenings
The Cygnus Pressurized Cargo Module for the OA-4 mission arrived at the Kennedy Space Center during August 2015 for processing in preparation for the upcoming CRS space station resupply mission to be launched from Florida in early December 2015. Credit: Orbital ATK
A commercial Cygnus cargo freighter has just arrived at the Kennedy Space Center (KSC) in Florida to begin intensive processing for a critical mission to deliver some four tons of science experiments and supplies to the International Space Station (ISS) atop an Atlas V rocket in early December – as manufacturer Orbital ATK takes a big step in ramping up activities to fulfill its station resupply commitments and recover from the catastrophic launch failure of the firms Antares rocket last October.
Taking advantage of the built in flexibility to launch Cygnus on a variety of rockets, Orbital ATK quickly contracted rocket maker United Launch Alliance (ULA) to propel the cargo ship as soon as practical on the venerable Atlas V – as Orbital simultaneously endeavors to reengineer the Antares and bring that vehicle back to full flight status in 2016.
Since the fastest and most robust path back to on orbital cargo delivery runs through Florida via an Atlas V, Orbital ATK teamed up with ULA to launch a minimum of one Cygnus with an option for more.
Cygnus is comprised of a pressurized cargo module (PCM) manufactured by Thales Alenia Space’s production facility in Turin, Italy and a service module (SM) manufactured at Orbital ATK’s Dulles, Virginia satellite manufacturing facility.
The PCM arrived on Monday, Aug. 11 and is now being processed for the flight dubbed OA-4 at KSC inside the Space Station Processing Facility (SSPF). After the SM arrives in October it will be mated to the PCM inside the SSPF.
The OA-4 Service Module (SM) undergoing deployment testing of one of its two UltraflexTM solar arrays at orbital ATK’s Dulles, Virginia satellite manufacturing facility. Orbital ATK’s Space Components Division supplies the Ultraflex arrays. Credit: Orbital ATK
The first Cygnus cargo mission should liftoff sometime late in the fourth quarter of 2015, perhaps as soon as Dec. 3, aboard an Atlas V 401 vehicle from Space Launch Complex 41 (SLC-41) at Cape Canaveral Air Force Station in Florida.
Since ULA’s Atlas V manifest was already fully booked, ULA managers told me that they worked diligently to find a way to manufacture and insert an additional Atlas V into the tight launch sequence flow at the Cape.
And since the station and its six person crews can’t survive and conduct their scientific research work without a steady train of cargo delivery missions from the station’s partner nations, Orbital ATK is “devoting maximum efforts” to get their Antares/Cygnus ISS resupply architecture back on track as fast as possible.
Orbital ATK holds a Commercial Resupply Services (CRS) contract from NASA worth $1.9 Billion to deliver 20,000 kilograms of research experiments, crew provisions, spare parts and hardware for eight Cygnus cargo delivery flights to the ISS.
However, the Cygnus missions were put on hold when the third operational Antares/Cygnus flight was destroyed in a raging inferno about 15 seconds after liftoff on the Orb-3 mission from launch pad 0A at NASA’s Wallops Flight Facility on Virginia’s eastern shore.
First stage propulsion system at base of Orbital Sciences Antares rocket appears to explode moments after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014, at 6:22 p.m. Credit: Ken Kremer – kenkremer.com
“We committed to NASA that we would resume CRS cargo delivery missions as soon as possible under a comprehensive ‘go-forward’ plan after the Antares launch failure last October,” said David W. Thompson, President and Chief Executive Officer of Orbital ATK.
“Since that time our team has been sharply focused on fulfilling that commitment. With a Cygnus mission slated for later this year and at least three missions to the Space Station planned in 2016, we are on track to meet our CRS cargo requirements for NASA.”
Orbital says they will deliver the full quantity of cargo specified in the CRS contract with NASA.
“Our team and our partners are devoting maximum efforts to ensuring the success of NASA’s ISS commercial cargo program.”
“We are committed to meeting all CRS mission requirements, and we are prepared to continue to supply the Space Station.”
This Cygnus launched atop Antares on Jan. 9, 2014 and docked on Jan. 12 Cygnus pressurized cargo module – side view – during exclusive visit by Ken Kremer/Universe Today to observe prelaunch processing by Orbital Sciences at NASA Wallops, VA. ISS astronauts will open this hatch to unload 2780 pounds of cargo. Docking mechanism hooks and latches to ISS at left. Credit: Ken Kremer – kenkremer.com
For the OA-4 cargo mission, Cygnus will be loaded with its heaviest cargo to date on nearly four tons.
The weightier cargo is possible because a longer version of Cygnus will be employed.
This mission will fly with the extended Cygnus Pressurized Cargo Module (PCM) which will carry approximately 3,500 kg or 7,700 pounds of supplies to station.
“This is a very exciting time for the Cygnus team at Orbital ATK,” said Frank DeMauro, vice president of Human Space Systems and program director of the Commercial Resupply Services program at Orbital ATK.
“Not only are we launching from Kennedy on an Atlas V for the first time, but this will also be the first flight of the Enhanced Cygnus, which includes a larger cargo module and a more mass-efficient service module.”
Use of the enhanced Cygnus in combination with the added thrust ULA V is a game changer enabling the Cygnus to carry its maximum possible cargo load for NASA.
“During our first three missions, we delivered 3,629 kilograms to the space station, about the weight of two F-150 pickup trucks,” said Frank DeMauro.
The OA-4 Cygnus alone will deliver some 3,500 kilograms.
Once in orbit, Cygnus fires its onboard thrusters to precisely guide itself close to the space station so that the astronauts can grapple it with the robotic arm and berth it to a port on the station.
Be sure to read Ken’s earlier eyewitness reports about last October’s Antares failure at NASA Wallops and ongoing reporting about Orbital ATK’s recovery efforts – all here at Universe Today.
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
Soviet era NK-33 engines refurbished as the AJ26 exactly like pictured here probably caused Antares’ rocket failure on Oct. 28, 2014. Orbital Sciences technicians at work on two AJ26 first stage engines at the base of an Antares rocket during exclusive visit by Ken Kremer/Universe Today at NASA Wallaps. These engines powered the successful Antares liftoff on Jan. 9, 2014 at NASA Wallops, Virginia bound for the ISS. Credit: Ken Kremer – kenkremer.com
The SpaceX Falcon 9 rocket and Dragon cargo spaceship dazzled in the moments after liftoff from Cape Canaveral, Florida, on June 28, 2015 but were soon doomed to a sudden catastrophic destruction barely two minutes later in the inset photo (left). Composite image includes up close launch photo taken from pad camera set at Space Launch Complex 40 at Cape Canaveral and mid-air explosion photo taken from the roof of the Vehicle Assembly Building (VAB) at NASA’s Kennedy Space Center, Florida as rocket was streaking to the International Space Station (ISS) on CRS-7 cargo resupply mission. Credit: Ken Kremer/kenkremer.com
The in-flight failure of a critical support strut inside the second stage liquid oxygen tank holding a high pressure helium tank in the Falcon 9 rocket, is the likely cause of the failed SpaceX launch three weeks ago on June 28, revealed SpaceX CEO and chief designer Elon Musk during a briefing for reporters held today, July 20, to explain why the critical cargo delivery run for NASA to the space station suddenly turned into a total disaster after a promising start.
The commercial booster and its cargo Dragon payload were unexpectedly destroyed by an overpressure event 139 seconds after a picture perfect blastoff from Space Launch Complex 40 at Cape Canaveral Air Force Station in Florida on June 28 at 10:21 a.m. EDT.
Musk emphasized that the failure analysis is still “preliminary” and an “initial assessment” based on the investigation thus far. SpaceX has led the investigation efforts under the oversight of the FAA with participation from prime customers NASA and the U.S. Air Force.
The root cause appears to be that the second stage strut holding the high pressure helium tank inside the 2nd stage broke at a bolt – far below its design specification and thereby allowing the tank to break free and swing away.
“The strut that we believe failed was designed and certified to handle 10,000 lbs of force, but failed at 2,000 lbs, a five-fold difference,” Musk explained.
“During acceleration of the rocket to 3.2 G’s, the strut holding down the helium tank failed. Helium was released, causing the over pressurization event.”
To date no other issues have been identified as possible failure modes, Musk elaborated.
The helium tanks are pressurized to 5500 psi and were breached during the over pressurization. The purpose of the helium tanks is to pressurize the first and second stage propellant tanks.
SpaceX Falcon 9 rocket explodes about 2 minutes after liftoff from Cape Canaveral Air Force Station in Florida on June 28, 2015. Credit: Ken Kremer/kenkremer.com
“We tested several hundred struts. On the outside they looked normal. But inside there was a problem,” Musk explained
“Detailed close-out photos of stage construction show no visible flaws or damage of any kind,” according to a SpaceX statement.
The struts are produced by an outside vendor that Musk would not identify. He added that in the future, SpaceX will likely choose a different vendor to manufacture the struts.
He said the struts were made from a type of stainless steel and would also likely be redesigned.
“The material of construction will be changed to Inconel,” Musk told me in response to a question.
Hundreds of the original type struts have been used to date on the first and second stages of the Falcon 9 with no issues. In the future, they will also be independently certified for use, by an outside contractor instead of the vendor.
The nine first stage Merlin 1D engines of the Falcon 9 were still firing nominally during the start of the mishap, said Musk. The first stage had nearly completed its planned firing duration when the explosion took place.
“The event happened very quickly, within 0.893 seconds,” Musk stated, from the first indication of an issue to loss of all telemetry.
“Preliminary analysis suggests the overpressure event in the upper stage liquid oxygen tank was initiated by a flawed piece of support hardware (a “strut”) inside the second stage,” noted SpaceX in a statement.
Video caption: Launch video of the CRS-7 launch on June 28, 2015 from a remote camera placed at Launch Complex 40. The launch would fail around two minutes later. Credit: Alex Polimeni/Spaceflight Now
The blastoff of the Dragon CRS-7 cargo mission for NASA was the first failure of the SpaceX Falcon 9 rocket after 18 straight successes and the firms first launch mishap since the failure of a Falcon 1 in 2008.
The SpaceX CRS-7 Dragon was loaded with over 4,000 pounds (1987 kg) of research experiments, an EVA spacesuit, water filtration equipment, spare parts, gear, computer equipment, high pressure tanks of oxygen and nitrogen supply gases, food, water and clothing for the astronaut and cosmonaut crews comprising Expeditions 44 and 45.
Umbilicals away and detaching from SpaceX Falcon 9 launch from Cape Canaveral, Florida, on June 28, 2015 that was doomed to disaster soon thereafter. Credit: Ken Kremer/kenkremer.com
The Dragon cargo freighter survived the explosion but was destroyed when it impacted the Atlantic Ocean.
“But the Dragon might have been saved if the parachutes had been deployed,” said Musk.
Unfortunately the software required to deploy the parachute was not loaded onboard.
“The new software required to deploy the parachutes will be included on all future Dragons, V1 and V2,” said Musk, referring to the cargo and crew versions of the SpaceX Dragon spaceship.
SpaceX Falcon 9 rocket and Dragon resupply spaceship explode about 2 minutes after liftoff from Cape Canaveral Air Force Station in Florida on June 28, 2015. Credit: Ken Kremer/kenkremer.com
The NASA cargo was valued at about $110 million. The launch itself was not insured.
The investigation board is reviewing data from over 3,000 telemetry channels as well as video and physical debris, he noted.
The next launch of a Falcon 9 will be postponed at least a few months until “no earlier than September” Musk indicated.
Two Falcon 9 launches had been set for August from Vandenberg AFB and Cape Canaveral. And the next launch to the ISS had been slated for September on the Dragon CRS-8 mission.
Musk said the next payload to be launched aboard a Falcon 9 has yet to be determined.
Overall CRS-7 was the seventh SpaceX commercial resupply services mission and the eighth trip by a Dragon spacecraft to the station since 2012.
CRS-7 marked the company’s seventh operational resupply mission to the ISS under a $1.6 Billion contract with NASA to deliver 20,000 kg (44,000 pounds) of cargo to the station during a dozen Dragon cargo spacecraft flights through 2016 under NASA’s original Commercial Resupply Services (CRS) contract.
Stay tuned here for Ken’s continuing Earth and planetary science and human spaceflight news.
SpaceX founder and CEO Elon Musk briefs reporters, including Universe Today, in Cocoa Beach, FL, during prior SpaceX Falcon 9 rocket blastoff from Cape Canaveral, FL. Credit: Ken Kremer/kenkremer.com
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Learn more about SpaceX, ULA, Mars rovers, Orion, Antares, MMS, NASA missions and more at Ken’s upcoming outreach events:
July 21/22: “SpaceX, Orion, Commercial crew, Curiosity explores Mars, MMS, Antares and more,” Kennedy Space Center Quality Inn, Titusville, FL, evenings/afternoon for July 22 Delta IV launch of USAF WGS-7 satellite
