butch wilmore

“What the hell are you doing?” How I learned to interview astronauts, scientists, and billionaires

butch wilmore, elon musk, Features, Interviews, scott kelly, Space / Tim Belzer / April 13, 2025

The best part about journalism is not collecting information. It’s sharing it.

Sometimes the best place to do an interview is in a clean room. Credit: Lee Hutchinson

I recently wrote a story about the wild ride of the Starliner spacecraft to the International Space Station last summer. It was based largely on an interview with the commander of the mission, NASA astronaut Butch Wilmore.

His account of Starliner’s thruster failures—and his desperate efforts to keep the vehicle flying on course—was riveting. In the aftermath of the story, many readers, people on social media, and real-life friends congratulated me on conducting a great interview. But truth be told, it was pretty much all Wilmore.

Essentially, when I came into the room, he was primed to talk. I’m not sure if Wilmore was waiting for me specifically to talk to, but he pretty clearly wanted to speak with someone about his experiences aboard the Starliner spacecraft. And he chose me.

So was it luck? I’ve been thinking about that. As an interviewer, I certainly don’t have the emotive power of some of the great television interviewers, who are masters of confrontation and drama. It’s my nature to avoid confrontation where possible. But what I do have on my side is experience, more than 25 years now, as well as preparation. I am also genuinely and completely interested in space. And as it happens, these values are important, too.

Interviewing is a craft one does not pick up overnight. During my career, I have had some funny, instructive, and embarrassing moments. Without wanting to seem pretentious or self-indulgent, I thought it might be fun to share some of those stories so you can really understand what it’s like on a reporter’s side of the cassette tape.

March 2003: Stephen Hawking

I had only been working professionally as a reporter at the Houston Chronicle for a few years (and as the newspaper’s science writer for less time still) when the opportunity to interview Stephen Hawking fell into my lap.

What a coup! He was only the world’s most famous living scientist, and he was visiting Texas at the invitation of a local billionaire named George Mitchell. A wildcatter and oilman, Mitchell had grown up in Galveston along the upper Texas coast, marveling at the stars as a kid. He studied petroleum engineering and later developed the controversial practice of fracking. In his later years, Mitchell spent some of his largesse on the pursuits of his youth, including astronomy and astrophysics. This included bringing Hawking to Texas more than half a dozen times in the 1990s and early 2000s.

For an interview with Hawking, one submitted questions in advance. That’s because Hawking was afflicted with Lou Gehrig’s disease and lost the ability to speak in 1985. A computer attached to his wheelchair cycled through letters and sounds, and Hawking clicked a button to make a selection, forming words and then sentences, which were sent to a voice synthesizer. For unprepared responses, it took a few minutes to form a single sentence.

George Mitchell and Stephen Hawking during a Texas visit. Credit: Texas A&M University

What to ask him? I had a decent understanding of astronomy, having majored in it as an undergraduate. But the readership of a metro newspaper was not interested in the Hubble constant or the Schwarzschild radius. I asked him about recent discoveries of the cosmic microwave background radiation anyway. Perhaps the most enduring response was about the war in Iraq, a prominent topic of the day. “It will be far more difficult to get out of Iraq than to get in,” he said. He was right.

When I met him at Texas A&M University, Hawking was gracious and polite. He answered a couple of questions in person. But truly, it was awkward. Hawking’s time on Earth was limited and his health failing, so it required an age to tap out even short answers. I can only imagine his frustration at the task of communication, which the vast majority of humans take for granted, especially because he had such a brilliant mind and so many deep ideas to share. And here I was, with my banal questions, stealing his time. As I stood there, I wondered whether I should stare at him while he composed a response. Should I look away? I felt truly unworthy.

In the end, it was fine. I even met Hawking a few more times, including at a memorable dinner at Mitchell’s ranch north of Houston, which spans tens of thousands of acres. A handful of the world’s most brilliant theoretical physicists were there. We would all be sitting around chatting, and Hawking would periodically chime in with a response to something brought up earlier. Later on that evening, Mitchell and Hawking took a chariot ride around the grounds. I wonder what they talked about?

Spring 2011: Jane Goodall and Sylvia Earle

By this point, I had written about science for nearly a decade at the Chronicle. In the early part of the year, I had the opportunity to interview noted chimpanzee scientist Jane Goodall and one of the world’s leading oceanographers, Sylvia Earle. Both were coming to Houston to talk about their research and their passion for conservation.

I spoke with Goodall by phone in advance of her visit, and she was so pleasant, so regal. By then, Goodall was 76 years old and had been studying chimpanzees in Gombe Stream National Park in Tanzania for five decades. Looking back over the questions I asked, they’re not bad. They’re just pretty basic. She gave great answers regardless. But there is only so much chemistry you can build with a person over the telephone (or Zoom, for that matter, these days). Being in person really matters in interviewing because you can read cues, and it’s easier to know when to let a pause go. The comfort level is higher. When you’re speaking with someone you don’t know that well, establishing a basic level of comfort is essential to making an all-important connection.

A couple of months later, I spoke with Earle in person at the Houston Museum of Natural Science. I took my older daughter, then nine years old, because I wanted her to hear Earle speak later in the evening. This turned out to be a lucky move for a couple of different reasons. First, my kid was inspired by Earle to pursue studies in marine biology. And more immediately, the presence of a curious 9-year-old quickly warmed Earle to the interview. We had a great discussion about many things beyond just oceanography.

President Barack Obama talks with Dr. Sylvia Earle during a visit to Midway Atoll on September 1, 2016. Credit: Barack Obama Presidential Library

The bottom line is that I remained a fairly pedestrian interviewer back in 2011. That was partly because I did not have deep expertise in chimpanzees or oceanography. And that leads me to another key for a good interview and establishing a rapport. It’s great if a person already knows you, but even if they don’t, you can overcome that by showing genuine interest or demonstrating your deep knowledge about a subject. I would come to learn this as I started to cover space more exclusively and got to know the industry and its key players better.

September 2014: Scott Kelly

To be clear, this was not much of an interview. But it is a fun story.

I spent much of 2014 focused on space for the Houston Chronicle. I pitched the idea of an in-depth series on the sorry state of NASA’s human spaceflight program, which was eventually titled “Adrift.” By immersing myself in spaceflight for months on end, I discovered a passion for the topic and knew that writing about space was what I wanted to do for the rest of my life. I was 40 years old, so it was high time I found my calling.

As part of the series, I traveled to Kazakhstan with a photographer from the Chronicle, Smiley Pool. He is a wonderful guy who had strengths in chatting up sources that I, an introvert, lacked. During the 13-day trip to Russia and Kazakhstan, we traveled with a reporter from Esquire named Chris Jones, who was working on a long project about NASA astronaut Scott Kelly. Kelly was then training for a yearlong mission to the International Space Station, and he was a big deal.

Jones was a tremendous raconteur and an even better writer—his words, my goodness. We had so much fun over those two weeks, sharing beer, vodka, and Kazakh food. The capstone of the trip was seeing the Soyuz TMA-14M mission launch from the Baikonur Cosmodrome. Kelly was NASA’s backup astronaut for the flight, so he was in quarantine alongside the mission’s primary astronaut. (This was Butch Wilmore, as it turns out). The launch, from a little more than a kilometer away, was still the most spectacular moment of spaceflight I’ve ever observed in person. Like, holy hell, the rocket was right on top of you.

Expedition 43 NASA Astronaut Scott Kelly walks from the Zvjozdnyj Hotel to the Cosmonaut Hotel for additional training, Thursday, March 19, 2015, in Baikonur, Kazakhstan. Credit: NASA/Bill Ingalls

Immediately after the launch, which took place at 1: 25 am local time, Kelly was freed from quarantine. This must have been liberating because he headed straight to the bar at the Hotel Baikonur, the nicest watering hole in the small, Soviet-era town. Jones, Pool, and I were staying at a different hotel. Jones got a text from Kelly inviting us to meet him at the bar. Our NASA minders were uncomfortable with this, as the last thing they want is to have astronauts presented to the world as anything but sharp, sober-minded people who represent the best of the best. But this was too good to resist.

By the time we got to the bar, Kelly and his companion, the commander of his forthcoming Soyuz flight, Gennady Padalka, were several whiskeys deep. The three of us sat across from Kelly and Padalka, and as one does at 3 am in Baikonur, we started taking shots. The astronauts were swapping stories and talking out of school. At one point, Jones took out his notebook and said that he had a couple of questions. To this, Kelly responded heatedly, “What the hell are you doing?”

Not conducting an interview, apparently. We were off the record. Well, until today at least.

We drank and talked for another hour or so, and it was incredibly memorable. At the time, Kelly was probably the most famous active US astronaut, and here I was throwing down whiskey with him shortly after watching a rocket lift off from the very spot where the Soviets launched the Space Age six decades earlier. In retrospect, this offered a good lesson that the best interviews are often not, in fact, interviews. To get the good information, you need to develop relationships with people, and you do that by talking with them person to person, without a microphone, often with alcohol.

Scott Kelly is a real one for that night.

September 2019: Elon Musk

I have spoken with Elon Musk a number of times over the years, but none was nearly so memorable as a long interview we did for my first book on SpaceX, called Liftoff. That summer, I made a couple of visits to SpaceX’s headquarters in Hawthorne, California, interviewing the company’s early employees and sitting in on meetings in Musk’s conference room with various teams. Because SpaceX is such a closed-up company, it was fascinating to get an inside look at how the sausage was made.

It’s worth noting that this all went down a few months before the onset of the COVID-19 pandemic. In some ways, Musk is the same person he was before the outbreak. But in other ways, he is profoundly different, his actions and words far more political and polemical.

Anyway, I was supposed to interview Musk on a Friday evening at the factory at the end of one of these trips. As usual, Musk was late. Eventually, his assistant texted, saying something had come up. She was desperately sorry, but we would have to do the interview later. I returned to my hotel, downbeat. I had an early flight the next morning back to Houston. But after about an hour, the assistant messaged me again. Musk had to travel to South Texas to get the Starship program moving. Did I want to travel with him and do the interview on the plane?

As I sat on his private jet the next day, late morning, my mind swirled. There would be no one else on the plane but Musk, his three sons (triplets, then 13 years old) and two bodyguards, and me. When Musk is in a good mood, an interview can be a delight. He is funny, sharp, and a good storyteller. When Musk is in a bad mood, well, an interview is usually counterproductive. So I fretted. What if Musk was in a bad mood? It would be a super-awkward three and a half hours on the small jet.

Two Teslas drove up to the plane, the first with Musk driving his boys and the second with two security guys. Musk strode onto the jet, saw me, and said he didn’t realize I was going to be on the plane. (A great start to things!) Musk then took out his phone and started a heated conversation about digging tunnels. By this point, I was willing myself to disappear. I just wanted to melt into the leather seat I was sitting in about three feet from Musk.

So much for a good mood for the interview.

As the jet climbed, the phone conversation got worse, but then Musk lost his connection. He put away his phone and turned to me, saying he was free to talk. His mood, almost as if by magic, changed. Since we were discussing the early days of SpaceX at Kwajalein, he gathered the boys around so they could hear about their dad’s earlier days. The interview went shockingly well, and at least part of the reason has to be that I knew the subject matter deeply, had prepared, and was passionate about it. We spoke for nearly two hours before Musk asked if he might have some time with his kids. They spent the rest of the flight playing video games, yucking it up.

April 2025: Butch Wilmore

When they’re on the record, astronauts mostly stick to a script. As a reporter, you’re just not going to get too much from them. (Off the record is a completely different story, of course, as astronauts are generally delightful, hilarious, and earnest people.)

Last week, dozens of journalists were allotted 10-minute interviews with Wilmore and, separately, Suni Williams. It was the first time they had spoken in depth with the media since their launch on Starliner and return to Earth aboard a Crew Dragon vehicle. As I waited outside Studio A at Johnson Space Center, I overheard Wilmore completing an interview with a Tennessee-based outlet, where he is from. As they wrapped up, the public affairs officer said he had just one more interview left and said my name. Wilmore said something like, “Oh good, I’ve been waiting to talk with him.”

That was a good sign. Out of all the interviews that day, it was good to know he wanted to speak with me. The easy thing for him to do would have been to use “astronaut speak” for 10 minutes and then go home. I was the last interview of the day.

As I prepared to speak with Wilmore and Williams, I didn’t want to ask the obvious questions they’d answered many times earlier. If you ask, “What was it like to spend nine months in space when you were expecting only a short trip?” you’re going to get a boring answer. Similarly, although the end of the mission was highly politicized by the Trump White House, two veteran NASA astronauts were not going to step on that landmine.

I wanted to go back to the root cause of all this, the problems with Starliner’s propulsion system. My strategy was simply to ask what it was like to fly inside the spacecraft. Williams gave me some solid answers. But Wilmore had actually been at the controls. And he apparently had been holding in one heck of a story for nine months. Because when I asked about the launch, and then what it was like to fly Starliner, he took off without much prompting.

Butch Wilmore has flown on four spacecraft: the Space Shuttle, Soyuz, Starliner, and Crew Dragon. Credit: NASA/Emmett Given

I don’t know exactly why Wilmore shared so much with me. We are not particularly close and have never interacted outside of an official NASA setting. But he knows of my work and interest in spaceflight. Not everyone at the space agency appreciates my journalism, but they know I’m deeply interested in what they’re doing. They know I care about NASA and Johnson Space Center. So I asked Wilmore a few smart questions, and he must have trusted that I would tell his story honestly and accurately, and with appropriate context. I certainly tried my best. After a quarter of a century, I have learned well that the most sensational stories are best told without sensationalism.

Even as we spoke, I knew the interview with Wilmore was one of the best I had ever done. A great scientist once told me that the best feeling in the world is making some little discovery in a lab and for a short time knowing something about the natural world that no one else knows. The equivalent, for me, is doing an interview and knowing I’ve got gold. And for a little while, before sharing it with the world, I’ve got that little piece of gold all to myself.

But I’ll tell you what. It’s even more fun to let the cat out of the bag. The best part about journalism is not collecting information. It’s sharing that information with the world.

Eric Berger is the senior space editor at Ars Technica, covering everything from astronomy to private space to NASA policy, and author of two books: Liftoff, about the rise of SpaceX; and Reentry, on the development of the Falcon 9 rocket and Dragon. A certified meteorologist, Eric lives in Houston.

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Starliner’s flight to the space station was far wilder than most of us thought

butch wilmore, Features, Space, starliner, suni williams / Mike M. / April 2, 2025

“Hey, this is a very precarious situation we’re in.”

NASA astronaut Butch Wilmore receives a warm welcome at Johnson Space Center’s Ellington Field in Houston from NASA astronauts Reid Wiseman and Woody Hoburg after completing a long-duration science mission aboard the International Space Station. Credit: NASA/Robert Markowitz

As it flew up toward the International Space Station last summer, the Starliner spacecraft lost four thrusters. A NASA astronaut, Butch Wilmore, had to take manual control of the vehicle. But as Starliner’s thrusters failed, Wilmore lost the ability to move the spacecraft in the direction he wanted to go.

He and his fellow astronaut, Suni Williams, knew where they wanted to go. Starliner had flown to within a stone’s throw of the space station, a safe harbor, if only they could reach it. But already, the failure of so many thrusters violated the mission’s flight rules. In such an instance, they were supposed to turn around and come back to Earth. Approaching the station was deemed too risky for Wilmore and Williams, aboard Starliner, as well as for the astronauts on the $100 billion space station.

But what if it was not safe to come home, either?

“I don’t know that we can come back to Earth at that point,” Wilmore said in an interview. “I don’t know if we can. And matter of fact, I’m thinking we probably can’t.”

Starliner astronauts meet with the media

On Monday, for the first time since they returned to Earth on a Crew Dragon vehicle two weeks ago, Wilmore and Williams participated in a news conference at Johnson Space Center in Houston. Afterward, they spent hours conducting short, 10-minute interviews with reporters from around the world, describing their mission. I spoke with both of them.

Many of the questions concerned the politically messy end of the mission, in which the Trump White House claimed it had rescued the astronauts after they were stranded by the Biden administration. This was not true, but it is also not a question that active astronauts are going to answer. They have too much respect for the agency and the White House that appoints its leadership. They are trained not to speak out of school. As Wilmore said repeatedly on Monday, “I can’t speak to any of that. Nor would I.”

So when Ars met with Wilmore at the end of the day—it was his final interview, scheduled for 4: 55 to 5: 05 pm in a small studio at Johnson Space Center—politics was not on the menu. Instead, I wanted to know the real story, the heretofore untold story of what it was really like to fly Starliner. After all, the problems with the spacecraft’s propulsion system precipitated all the other events—the decision to fly Starliner home without crew, the reshuffling of the Crew-9 mission, and their recent return in March after nine months in space.

I have known Wilmore a bit for more than a decade. I was privileged to see his launch on a Soyuz rocket from Kazakhstan in 2014, alongside his family. We both are about to become empty nesters, with daughters who are seniors in high school, soon to go off to college. Perhaps because of this, Wilmore felt comfortable sharing his experiences and anxieties from the flight. We blew through the 10-minute interview slot and ended up talking for nearly half an hour.

It’s a hell of a story.

Launch and a cold night

Boeing’s Starliner spacecraft faced multiple delays before the vehicle’s first crewed mission, carrying NASA astronauts Butch Wilmore and Suni Williams launched on June 5, 2024. These included a faulty valve on the Atlas V rocket’s upper stage, and then a helium leak inside Boeing’s Starliner spacecraft.

The valve issue, in early May, stood the mission down long enough that Wilmore asked to fly back to Houston for additional time in a flight simulator to keep his skills fresh. Finally, with fine weather, the Starliner Crew Flight Test took off from Cape Canaveral, Florida. It marked the first human launch on the Atlas V rocket, which had a new Centaur upper stage with two engines.

Suni Williams’ first night on Starliner was quite cold. Credit: NASA/Helen Arase Vargas

Sunita “Suni” Williams: “Oh man, the launch was awesome. Both of us looked at each other like, ‘Wow, this is going just perfectly.’ So the ride to space and the orbit insertion burn, all perfect.”

Barry “Butch” Wilmore: “In simulations, there’s always a deviation. Little deviations in your trajectory. And during the launch on Shuttle STS-129 many years ago, and Soyuz, there’s the similar type of deviations that you see in this trajectory. I mean, it’s always correcting back. But this ULA Atlas was dead on the center. I mean, it was exactly in the crosshairs, all the way. It was much different than what I’d expected or experienced in the past. It was exhilarating. It was fantastic. Yeah, it really was. The dual-engine Centaur did have a surge. I’m not sure ULA knew about it, but it was obvious to us. We were the first to ride it. Initially we asked, ‘Should that be doing that? This surging?’ But after a while, it was kind of soothing. And again, we were flying right down the middle.”

After Starliner separated from the Atlas V rocket, Williams and Wilmore performed several maneuvering tests and put the vehicle through its paces. Starliner performed exceptionally well during these initial tests on day one.

Wilmore: “The precision, the ability to control to the exact point that I wanted, was great. There was very little, almost imperceptible cross-control. I’ve never given a handling qualities rating of “one,” which was part of a measurement system. To take a qualitative test and make a quantitative assessment. I’ve never given a one, ever, in any test I’ve ever done, because nothing’s ever deserved a one. Boy, I was tempted in some of the tests we did. I didn’t give a one, but it was pretty amazing.”

Following these tests, the crew attempted to sleep for several hours ahead of their all-important approach and docking with the International Space Station on the flight’s second day. More so even than launch or landing, the most challenging part of this mission, which would stress Starliner’s handling capabilities as well as its navigation system, would come as it approached the orbiting laboratory.

Williams: “The night that we spent there in the spacecraft, it was a little chilly. We had traded off some of our clothes to bring up some equipment up to the space station. So I had this small T-shirt thing, long-sleeve T-shirt, and I was like, ‘Oh my gosh, I’m cold.’ Butch is like, ‘I’m cold, too.’ So, we ended up actually putting our boots on, and then I put my spacesuit on. And then he’s like, maybe I want mine, too. So we both actually got in our spacesuits. It might just be because there were two people in there.”

Starliner was designed to fly four people to the International Space Station for six-month stays in orbit. But for this initial test flight, there were just two people, which meant less body heat. Wilmore estimated that it was about 50° Fahrenheit in the cabin.

Wilmore: “It was definitely low 50s, if not cooler. When you’re hustling and bustling, and doing things, all the tests we were doing after launch, we didn’t notice it until we slowed down. We purposely didn’t take sleeping bags. I was just going to bungee myself to the bulkhead. I had a sweatshirt and some sweatpants, and I thought, I’m going to be fine. No, it was frigid. And I even got inside my space suit, put the boots on and everything, gloves, the whole thing. And it was still cold.”

Time to dock with the space station

After a few hours of fitful sleep, Wilmore decided to get up and start working to get his blood pumping. He reviewed the flight plan and knew it was going to be a big day. Wilmore had been concerned about the performance of the vehicle’s reaction control system thrusters. There are 28 of them. Around the perimeter of Starliner’s service module, at the aft of the vehicle, there are four “doghouses” equally spaced around the vehicle.

Each of these doghouses contains seven small thrusters for maneuvering. In each doghouse, two thrusters are aft-facing, two are forward-facing, and three are in different radial directions (see an image of a doghouse, with the cover removed, here). For docking, these thrusters are essential. There had been some problems with their performance during an uncrewed flight test to the space station in May 2022, and Wilmore had been concerned those issues might crop up again.

Boeing’s Starliner spacecraft is pictured docked to the International Space Station. One of the four doghouses is visible on the service module. Credit: NASA

Wilmore: “Before the flight we had a meeting with a lot of the senior Boeing executives, including the chief engineer. [This was Naveed Hussain, chief engineer for Boeing’s Defense, Space, and Security division.] Naveed asked me what is my biggest concern? And I said the thrusters and the valves because we’d had failures on the OFT missions. You don’t get the hardware back. (Starliner’s service module is jettisoned before the crew capsule returns from orbit). So you’re just looking at data and engineering judgment to say, ‘OK, it must’ve been FOD,’ (foreign object debris) or whatever the various issues they had. And I said that’s what concerns me the most. Because in my mind, I’m thinking, ‘If we lost thrusters, we could be in a situation where we’re in space and can’t control it.’ That’s what I was thinking. And oh my, what happened? We lost the first thruster.”

When vehicles approach the space station, they use two imaginary lines to help guide their approach. These are the R-bar, which is a line connecting the space station to the center of Earth. The “R” stands for radius. Then there is the V-bar, which is the velocity vector of the space station. Due to thruster issues, as Starliner neared the V-bar about 260 meters (850 feet) from the space station, Wilmore had to take manual control of the vehicle.

Wilmore: “As we get closer to the V-bar, we lose our second thruster. So now we’re single fault tolerance for the loss of 6DOF control. You understand that?”

Here things get a little more complicated if you’ve never piloted anything. When Wilmore refers to 6DOF control, he means six degrees of freedom—that is, the six different movements possible in three-dimensional space: forward/back, up/down, left/right, yaw, pitch, and roll. With Starliner’s four doghouses and their various thrusters, a pilot is able to control the spacecraft’s movement across these six degrees of freedom. But as Starliner got to within a few hundred meters of the station, a second thruster failed. The condition of being “single fault” tolerant means that the vehicle could sustain just one more thruster failure before being at risk of losing full control of Starliner’s movement. This would necessitate a mandatory abort of the docking attempt.

Wilmore: “We’re single fault tolerant, and I’m thinking, ‘Wow, we’re supposed to leave the space station.’ Because I know the flight rules. I did not know that the flight directors were already in discussions about waiving the flight rule because we’ve lost two thrusters. We didn’t know why. They just dropped.”

The heroes in Mission Control

As part of the Commercial Crew program, the two companies providing transportation services for NASA, SpaceX, and Boeing, got to decide who would fly their spacecraft. SpaceX chose to operate its Dragon vehicles out of a control center at the company’s headquarters in Hawthorne, California. Boeing chose to contract with NASA’s Mission Control at Johnson Space Center in Houston to fly Starliner. So at this point, the vehicle is under the purview of a Flight Director named Ed Van Cise. This was the capstone mission of his 15-year career as a NASA flight director.

Wilmore: “Thankfully, these folks are heroes. And please print this. What do heroes look like? Well, heroes put their tank on and they run into a fiery building and pull people out of it. That’s a hero. Heroes also sit in their cubicle for decades studying their systems, and knowing their systems front and back. And when there is no time to assess a situation and go and talk to people and ask, ‘What do you think?’ they know their system so well they come up with a plan on the fly. That is a hero. And there are several of them in Mission Control.”

From the outside, as Starliner approached the space station last June, we knew little of this. By following NASA’s webcast of the docking, it was clear there were some thruster issues and that Wilmore had to take manual control. But we did not know that in the final minutes before docking, NASA waived the flight rules about loss of thrusters. According to Wilmore and Williams, the drama was only beginning at this point.

Wilmore: “We acquired the V-bar, and I took over manual control. And then we lose the third thruster. Now, again, they’re all in the same direction. And I’m picturing these thrusters that we’re losing. We lost two bottom thrusters. You can lose four thrusters, if they’re top and bottom, but you still got the two on this side, you can still maneuver. But if you lose thrusters in off-orthogonal, the bottom and the port, and you’ve only got starboard and top, you can’t control that. It’s off-axis. So I’m parsing all this out in my mind, because I understand the system. And we lose two of the bottom thrusters. We’ve lost a port thruster. And now we’re zero-fault tolerant. We’re already past the point where we were supposed to leave, and now we’re zero-fault tolerant and I’m manual control. And, oh my, the control is sluggish. Compared to the first day, it is not the same spacecraft. Am I able to maintain control? I am. But it is not the same.”

At this point in the interview, Wilmore went into some wonderful detail.

Wilmore: “And this is the part I’m sure you haven’t heard. We lost the fourth thruster. Now we’ve lost 6DOF control. We can’t maneuver forward. I still have control, supposedly, on all the other axes. But I’m thinking, the F-18 is a fly-by-wire. You put control into the stick, and the throttle, and it sends the signal to the computer. The computer goes, ‘OK, he wants to do that, let’s throw that out aileron a bit. Let’s throw that stabilizer a bit. Let’s pull the rudder there.’ And it’s going to maintain balanced flight. I have not even had a reason to think, how does Starliner do this, to maintain a balance?”

This is a very precarious situation we’re in

Essentially, Wilmore could not fully control Starliner any longer. But simply abandoning the docking attempt was not a palatable solution. Just as the thrusters were needed to control the vehicle during the docking process, they were also necessary to position Starliner for its deorbit burn and reentry to Earth’s atmosphere. So Wilmore had to contemplate whether it was riskier to approach the space station or try to fly back to Earth. Williams was worrying about the same thing.

Williams: “There was a lot of unsaid communication, like, ‘Hey, this is a very precarious situation we’re in.’ I think both of us overwhelmingly felt like it would be really nice to dock to that space station that’s right in front of us. We knew that they [Mission Control] were working really hard to be able to keep communication with us, and then be able to send commands. We were both thinking, what if we lose communication with the ground? So NORDO Con Ops (this means flying a vehicle without a radio), and we didn’t talk about it too much, but we already had synced in our mind that we should go to the space station. This is our place that we need to probably go to, to have a conversation because we don’t know exactly what is happening, why the thrusters are falling off, and what the solution would be.”

Wilmore: “I don’t know that we can come back to Earth at that point. I don’t know if we can. And matter of fact, I’m thinking we probably can’t. So there we are, loss of 6DOF control, four aft thrusters down, and I’m visualizing orbital mechanics. The space station is nose down. So we’re not exactly level with the station, but below it. If you’re below the station, you’re moving faster. That’s orbital mechanics. It’s going to make you move away from the station. So I’m doing all of this in my mind. I don’t know what control I have. What if I lose another thruster? What if we lose comm? What am I going to do?”

One of the other challenges at this point, in addition to holding his position relative to the space station, was keeping Starliner’s nose pointed directly at the orbital laboratory.

Williams: “Starliner is based on a vision system that looks at the space station and uses the space station as a frame of reference. So if we had started to fall off and lose that, which there’s a plus or minus that we can have; we didn’t lose the station ever, but we did start to deviate a little bit. I think both of us were getting a bit nervous then because the system would’ve automatically aborted us.”

After Starliner lost four of its 28 reaction control system thrusters, Van Cise and this team in Houston decided the best chance for success was resetting the failed thrusters. This is, effectively, a fancy way of turning off your computer and rebooting it to try to fix the problem. But it meant Wilmore had to go hands-off from Starliner’s controls.

Imagine that. You’re drifting away from the space station, trying to maintain your position. The station is your only real lifeline because if you lose the ability to dock, the chance of coming back in one piece is quite low. And now you’re being told to take your hands off the controls.

Wilmore: “That was not easy to do. I have lived rendezvous orbital dynamics going back decades. [Wilmore is one of only two active NASA astronauts who has experience piloting the space shuttle.] Ray Bigonesse is our rendezvous officer. What a motivated individual. Primarily him, but me as well, we worked to develop this manual rendezvous capability over the years. He’s a volunteer fireman, and he said, ‘Hey, I’m coming off shift at 5: 30 Saturday morning; will you meet me in the sim?’ So we’d meet on Saturdays. We never got to the point of saying lose four thrusters. Who would’ve thought that, in the same direction? But we’re in there training, doing things, playing around. That was the preparation.”

All of this training meant Wilmore felt like he was in the best position to fly Starliner, and he did not relish the thought of giving up control. But finally, when he thought the spacecraft was temporarily stable enough, Wilmore called down to Mission Control, “Hands off.” Almost immediately, flight controllers sent a signal to override Starliner’s flight computer and fire the thrusters that had been turned off. Two of the four thrusters came back online.

Wilmore: “Now we’re back to single-fault tolerant. But then we lose a fifth jet. What if we’d have lost that fifth jet while those other four were still down? I have no idea what would’ve happened. I attribute to the providence of the Lord getting those two jets back before that fifth one failed. So we’re down to zero-fault tolerant again. I can still maintain control. Again, sluggish. Not only was the control different on the visual, what inputs and what it looked like, but we could hear it. The valve opening and closing. When a thruster would fire, it was like a machine gun.”

We’re probably not flying home in Starliner

Mission Control decided that it wanted to try to recover the failed thrusters again. After Wilmore took his hands off the controls, this process recovered all but one of them. At that point, the vehicle could be flown autonomously, as it was intended to be. When asked to give up control of the vehicle for its final approach to the station, Wilmore said he was apprehensive about doing so. He was concerned that if the system went into automation mode, it may not have been possible to get it back in manual mode. After all that had happened, he wanted to make sure he could take control of Starliner again.

Butch Wilmore and Suni Williams landed in a Crew Dragon spacecraft in March. Dolphins were among their greeters. Credit: NASA

Wilmore: “I was very apprehensive. In earlier sims, I had even told the flight directors, ‘If we get in a situation where I got to give it back to auto, I may not.’ And they understood. Because if I’ve got a mode that’s working, I don’t want to give it up. But because we got those jets back, I thought, ‘OK, we’re only down one.’ All this is going through my mind in real time. And I gave it back. And of course, we docked.”

Williams: “I was super happy. If you remember from the video, when we came into the space station, I did this little happy dance. One, of course, just because I love being in space and am happy to be on the space station and [with] great friends up there. Two, just really happy that Starliner docked to the space station. My feeling at that point in time was like, ‘Oh, phew, let’s just take a breather and try to understand what happened.'”

“There are really great people on our team. Our team is huge. The commercial crew program, NASA and Boeing engineers, were all working hard to try to understand, to try to decide what we might need to do to get us to come back in that spacecraft. At that point, we also knew it was going to take a little while. Everything in this business takes a little while, like you know, because you want to cross the T’s and dot the I’s and make sure. I think the decision at the end of the summer was the right decision. We didn’t have all the T’s crossed; we didn’t have all the I’s dotted. So do we take that risk where we don’t need to?”

Wilmore added that he felt pretty confident, in the aftermath of docking to the space station, that Starliner probably would not be their ride home.

Wilmore: “I was thinking, we might not come home in the spacecraft. We might not. And one of the first phone calls I made was to Vincent LaCourt, the ISS flight director, who was one of the ones that made the call about waiving the flight rule. I said, ‘OK, what about this spacecraft, is it our safe haven?‘”

It was unlikely to happen, but if some catastrophic space station emergency occurred while Wilmore and Williams were in orbit, what were they supposed to do? Should they retreat to Starliner for an emergency departure, or cram into one of the other vehicles on station, for which they did not have seats or spacesuits? LaCourt said they should use Starliner as a safe haven for the time being. Therein followed a long series of meetings and discussions about Starliner’s suitability for flying crew back to Earth. Publicly, NASA and Boeing expressed confidence in Starliner’s safe return with crew. But Williams and Wilmore, who had just made that harrowing ride, felt differently.

Wilmore: “I was very skeptical, just because of what we’d experienced. I just didn’t see that we could make it. I was hopeful that we could, but it would’ve been really tough to get there, to where we could say, ‘Yeah, we can come back.'”

So they did not.

Starliner’s flight to the space station was far wilder than most of us thought Read More »

Crew-10 launches, finally clearing the way for Butch and Suni to fly home

butch wilmore, international space station, NASA, Space, suni williams / Mike M. / March 15, 2025

A Falcon 9 rocket launched four astronauts safely into orbit on Friday evening, marking the official beginning of the Crew-10 mission to the International Space Station.

Although any crew launch into orbit is notable, this mission comes with an added bit of importance as its success clears the way for two NASA astronauts, Butch Wilmore and Suni Williams, to finally return home from space after a saga spanning nine months.

Friday’s launch came two days after an initial attempt was scrubbed on Wednesday evening. This was due to a hydraulic issue with the ground systems that handle the Falcon 9 rocket at Launch Complex 39A in Florida.

There were no technical issues on Friday, and with clear skies NASA astronauts Anne McClain and Nichole Ayers, Japanese astronaut Takuya Onishi, and Roscosmos cosmonaut Kirill Peskov rocketed smoothly into orbit.

If all goes well, the Crew Dragon spacecraft carrying the four astronauts will dock with the space station at 11: 30 pm ET on Saturday. They will spend about six months there.

A long, strange trip

Following their arrival at the space station, the members of Crew-10 will participate in a handover ceremony with the four astronauts of Crew-9, which includes Wilmore and Williams. This will clear the members of Crew 9 for departure from the station as early as next Wednesday, March 19, pending good weather in the waters surrounding Florida for splashdown of Dragon.

Crew-10 launches, finally clearing the way for Butch and Suni to fly home Read More »

NASA nears decision on what to do with Boeing’s troubled Starliner spacecraft

Boeing, butch wilmore, commercial crew, Commercial space, human spaceflight, international space station, NASA, Science, Space, spacex, starliner, suni williams / Mike M. / July 26, 2024

Boeing's Strainer spacecraft is seen docked at the International Space Station in this picture taken July 3. — Enlarge / Boeing’s Strainer spacecraft is seen docked at the International Space Station in this picture taken July 3.

The astronauts who rode Boeing’s Starliner spacecraft to the International Space Station last month still don’t know when they will return to Earth.

Astronauts Butch Wilmore and Suni Williams have been in space for 51 days, six weeks longer than originally planned, as engineers on the groundwork through problems with Starliner’s propulsion system.

The problems are twofold. The spacecraft’s reaction control thrusters overheated, and some of them shut off as Starliner approached the space station June 6. A separate, although perhaps related, problem involves helium leaks in the craft’s propulsion system.

On Thursday, NASA and Boeing managers said they still plan to bring Wilmore and Williams home on the Starliner spacecraft. In the last few weeks, ground teams completed testing of a thruster on a test stand at White Sands, New Mexico. This weekend, Boeing and NASA plan to fire the spacecraft’s thrusters in orbit to check their performance while docked at the space station.

“I think we’re starting to close in on those final pieces of flight rationale to make sure that we can come home safely, and that’s our primary focus right now,” Stich said.

The problems have led to speculation that NASA might decide to return Wilmore and Williams to Earth in a SpaceX Crew Dragon spacecraft. There’s one Crew Dragon currently docked at the station, and another one is slated to launch with a fresh crew next month. Steve Stich, manager of NASA’s commercial crew program, said the agency has looked at backup plans to bring the Starliner crew home on a SpaceX capsule, but the main focus is still to have the astronauts fly home aboard Starliner.

“Our prime option is to complete the mission,” Stich said. “There are a lot of good reasons to complete this mission and bring Butch and Suni home on Starliner. Starliner was designed, as a spacecraft, to have the crew in the cockpit.”

Starliner launched from Cape Canaveral Space Force Station in Florida on June 5. Wilmore and Williams are the first astronauts to fly into space on Boeing’s commercial crew capsule, and this test flight is intended to pave the way for future operational flights to rotate crews of four to and from the International Space Station.

Once NASA fully certifies Starliner for operational missions, the agency will have two human-rated spaceships for flights to the station. SpaceX’s Crew Dragon has been flying astronauts since 2020.

Tests, tests, and more tests

NASA has extended the duration of the Starliner test flight to conduct tests and analyze data in an effort to gain confidence in the spacecraft’s ability to safely bring its crew home and to better understand the root causes of the overheating thrusters and helium leaks. These problems are inside Starliner’s service module, which is jettisoned to burn up in the atmosphere during reentry, while the reusable crew module, with the astronauts inside, parachutes to an airbag-cushioned landing.

The most important of these tests was a series of test-firings of a Starliner thruster on the ground. This thruster was taken from a set of hardware slated to fly on a future Starlink mission, and engineers put it through a stress test, firing it numerous times to replicate the sequence of pulses it would see in flight. The testing simulated two sequences of flying up to the space station, and five sequences the thruster would execute during undocking and a deorbit burn for return to Earth.

“This thruster has seen quite a bit of pulses, maybe even more than what we would anticipate we would see during a flight, and more aggressive in terms of two uphills and five downhills,” Stich said. “What we did see in the thruster is the same kind of thrust degradation that we’re seeing on orbit. In a number of the thrusters (on Starliner), we’re seeing reduced thrust, which is important.”

Starliner’s flight computer shut off five of the spacecraft’s 28 reaction control system thrusters, produced by Aerojet Rocketdyne, during the rendezvous with the space station last month. Four of the five thrusters were recovered after overheating and losing thrust, but officials have declared one of the thrusters unusable.

The thruster tested on the ground showed similar behavior. Inspections of the thruster at White Sands showed bulging in a Teflon seal in an oxidizer valve, which could restrict the flow of nitrogen tetroxide propellant. The thrusters, each generating about 85 pounds of thrust, consume the nitrogen tetroxide, or NTO, oxidizer and mix it with hydrazine fuel for combustion.

A poppet valve, similar to an inflation valve on a tire, is designed to open and close to allow nitrogen tetroxide to flow into the thruster.

“That poppet has a Teflon seal at the end of it,” Nappi said. “Through the heating and natural vacuum that occurs with the thruster firing, that poppet seal was deformed and actually bulged out a little bit.”

Stich said engineers are evaluating the integrity of the Teflon seal to determine if it could remain intact through the undocking and deorbit burn of the Starliner spacecraft. The thrusters aren’t needed while Starliner is attached to the space station.

“Could that particular seal survive the rest of the flight? That’s the important part,” Stich said.

NASA nears decision on what to do with Boeing’s troubled Starliner spacecraft Read More »

Faulty valve scuttles Starliner’s first crew launch

atlas v, Boeing, butch wilmore, commercial crew, human spaceflight, international space station, NASA, Security, Space, starliner, suni williams, united launch alliance / Rejus Almole / May 7, 2024

Enlarge / The Atlas V rocket and Starliner spacecraft on their launch pad Monday.

Astronauts Butch Wilmore and Suni Williams climbed into their seats inside Boeing’s Starliner spacecraft Monday night in Florida, but trouble with the capsule’s Atlas V rocket kept the commercial ship’s long-delayed crew test flight on the ground.

Around two hours before launch time, shortly after 8: 30 pm EDT (00: 30 UTC), United Launch Alliance’s launch team stopped the countdown. “The engineering team has evaluated, the vehicle is not in a configuration where we can proceed with flight today,” said Doug Lebo, ULA’s launch conductor.

The culprit was a misbehaving valve on the rocket’s Centaur upper stage, which has two RL10 engines fed by super-cold liquid hydrogen and liquid oxygen propellants.

“We saw a self-regulating valve on the LOX (liquid oxygen) side had a bit of a buzz; it was moving in a strange behavior,” said Steve Stich, NASA’s commercial crew program manager. “The flight rules had been laid out for this flight ahead of time. With the crew at the launch pad, the proper action was to scrub.”

The next opportunity to launch Starliner on its first crew test flight will be Friday night at 9 pm EDT (01: 00 UTC Saturday). NASA announced overnight that officials decided to skip a launch opportunity Tuesday night to allow engineers more time to study the valve problem and decide whether they need to replace it.

Work ahead

Everything else was going smoothly in the countdown Monday night. This mission will also be the first time astronauts have flown on ULA’s Atlas V rocket, which has logged 99 successful flights since 2002. It is the culmination of nearly a decade-and-a-half of development by Boeing, which has a $4.2 billion contract with NASA to ready Starliner for crew missions, then carry out six long-duration crew ferry flights to and from the International Space Station.

This crew test flight will last at least eight days, taking Wilmore and Williams to the space station to verify Starliner’s readiness for operational missions. Once Starliner flies, NASA will have two human-rated spacecraft on contract. SpaceX’s Crew Dragon has been in service since 2020.

When officials scrubbed Monday night’s launch attempt, Wilmore and Williams were already aboard the Starliner spacecraft on top of the Atlas V rocket at Cape Canaveral Space Force Station, Florida. The Boeing and ULA support team helped them out of the capsule and drove them back to crew quarters at the nearby Kennedy Space Center to wait for the next launch attempt.

“I promised Butch and Suni a boring evening,” said Tory Bruno, ULA’s CEO. “I didn’t mean for it to be quite this boring, but we’re going to follow our rules, and we’re going to make sure that the crew is safe.”

When the next launch attempt actually occurs depends on whether ULA engineers determine they can resolve the problem without rolling the Atlas V rocket back to its hangar for repairs.

The valve in question vents gas from the liquid oxygen tank on the Centaur upper stage to maintain the tank at proper pressures. This is important for two reasons. The tank needs to be at the correct pressure for the RL10 engines to receive propellant during the flight, and the Centaur upper stage itself has ultra-thin walls to reduce weight, and requires pressure to maintain structural integrity.

Faulty valve scuttles Starliner’s first crew launch Read More »