Federal Aviation Administration

spacex-is-about-to-launch-starship-again—the-faa-will-be-more-forgiving-this-time

SpaceX is about to launch Starship again—the FAA will be more forgiving this time

The rocket for SpaceX's fourth full-scale Starship test flight awaits liftoff from Starbase, the company's private launch base in South Texas.

Enlarge / The rocket for SpaceX’s fourth full-scale Starship test flight awaits liftoff from Starbase, the company’s private launch base in South Texas.

SpaceX

The Federal Aviation Administration approved the commercial launch license for the fourth test flight of SpaceX’s Starship rocket Tuesday, with liftoff from South Texas targeted for just after sunrise Thursday.

“The FAA has approved a license authorization for SpaceX Starship Flight 4,” the agency said in a statement. “SpaceX met all safety and other licensing requirements for this test flight.”

Shortly after the FAA announced the launch license, SpaceX confirmed plans to launch the fourth test flight of the world’s largest rocket at 7: 00 am CDT (12: 00 UTC) Thursday. The launch window runs for two hours.

This flight follows three prior demonstration missions, each progressively more successful, of SpaceX’s privately developed mega-rocket. The last time Starship flew—on March 14—it completed an eight-and-a-half minute climb into space, but the ship was unable to maneuver itself as it coasted nearly 150 miles (250 km) above Earth. This controllability problem caused the rocket to break apart during reentry.

On Thursday’s flight, SpaceX officials will expect the ascent portion of the test flight to be similarly successful to the launch in March. The objectives this time will be to demonstrate Starship’s ability to survive the most extreme heating of reentry, when temperatures peak at 2,600° Fahrenheit (1,430° Celsius) as the vehicle plunges into the atmosphere at more than 20 times the speed of sound.

SpaceX officials also hope to see the Super Heavy booster guide itself toward a soft splashdown in the Gulf of Mexico just offshore from the company’s launch site, known as Starbase, in Cameron County, Texas.

“The fourth flight test turns our focus from achieving orbit to demonstrating the ability to return and reuse Starship and Super Heavy,” SpaceX wrote in an overview of the mission.

Last month, SpaceX completed a “wet dress rehearsal” at Starbase, where the launch team fully loaded the rocket with cryogenic methane and liquid oxygen propellants. Before the practice countdown, SpaceX test-fired the booster and ship at the launch site. More recently, technicians installed components of the rocket’s self-destruct system, which would activate to blow up the rocket if it flies off course.

Then, on Tuesday, SpaceX lowered the Starship upper stage from the top of the Super Heavy booster, presumably to perform final touch-ups to the ship’s heat shield, composed of 18,000 hexagonal ceramic tiles to protect its stainless-steel structure during reentry. Ground teams were expected to raise the ship, or upper stage, back on top of the booster sometime Wednesday, returning the rocket to its full height of 397 feet (121 meters) ahead of Thursday morning’s launch window.

The tick-tock of Starship’s fourth flight

If all goes according to plan, SpaceX’s launch team will start loading 10 million pounds of super-cold propellants into the rocket around 49 minutes before liftoff Thursday. The methane and liquid oxygen will first flow into the smaller tanks on the ship, then into the larger tanks on the booster.

The rocket should be fully loaded about three minutes prior to launch, and, following a sequence of automated checks, the computer controlling the countdown will give the command to light the booster’s 33 Raptor engines. Three seconds later, the rocket will begin its vertical climb off the launch mount, with its engines capable of producing more than 16 million pounds of thrust at full power.

Heading east from the Texas Gulf Coast, the rocket will exceed the speed of sound in about a minute, then begin shutting down its 33 main engines around 2 minutes and 41 seconds after liftoff. Then, just as the Super Heavy booster jettisons to begin a descent back to Earth, Starship’s six Raptor engines will ignite to continue pushing the upper portion of the rocket into space. Starship’s engines are expected to burn until T+ 8 minutes, 23 seconds, accelerating the rocket to near-orbital velocity with enough energy to fly an arcing trajectory halfway around the world to the Indian Ocean.

All of this will be similar to the events of the last Starship launch in March. What differs in the flight plan this time involves the attempts to steer the booster and ship back to Earth. This is important to lay the groundwork for future flights, when SpaceX wants to bring the Super Heavy booster—the size of the fuselage of a Boeing 747 jumbo jet—to a landing back at its launch pad. Eventually, SpaceX also intends to recover reusable Starships back at Starbase or other spaceports.

This infographic released by SpaceX shows the flight profile for SpaceX's fourth Starship launch.

Enlarge / This infographic released by SpaceX shows the flight profile for SpaceX’s fourth Starship launch.

SpaceX

Based on the results of the March test flight, SpaceX still has a lot to prove in these areas. On that flight, the engines on the Super Heavy booster could not complete all the burns required to guide the rocket toward the splashdown zone in the Gulf of Mexico. The booster lost control as it plummeted toward the ocean.

Engineers traced the failure to blockage in a filter where liquid oxygen flows into the Raptor engines. Notably, a similar problem occurred on the second Starship test flight last November. The Super Heavy booster awaiting launch Thursday has additional hardware to improve propellant filtration capabilities, according to SpaceX. The company also implemented “operational changes” on the booster for the upcoming test flight, including to jettison the Super Heavy’s staging ring, which sits between the booster and ship during launch, to reduce the rocket’s mass during descent.

SpaceX has a lot of experience bringing back its fleet of Falcon 9 boosters. The company now boasts a streak of more than 240 successful rocket landings in a row, so it’s reasonable to expect SpaceX will overcome the challenge of recovering the larger Super Heavy booster.

SpaceX is about to launch Starship again—the FAA will be more forgiving this time Read More »

we-take-a-stab-at-decoding-spacex’s-ever-changing-plans-for-starship-in-florida

We take a stab at decoding SpaceX’s ever-changing plans for Starship in Florida

SpaceX's Starship tower (left) at Launch Complex 39A dwarfs the launch pad for the Falcon 9 rocket (right).

Enlarge / SpaceX’s Starship tower (left) at Launch Complex 39A dwarfs the launch pad for the Falcon 9 rocket (right).

There are a couple of ways to read the announcement from the Federal Aviation Administration that it’s kicking off a new environmental review of SpaceX’s plan to launch the most powerful rocket in the world from Florida.

The FAA said on May 10 that it plans to develop an Environmental Impact Statement (EIS) for SpaceX’s proposal to launch Starships from NASA’s Kennedy Space Center in Florida. The FAA ordered this review after SpaceX updated the regulatory agency on the projected Starship launch rate and the design of the ground infrastructure needed at Launch Complex 39A (LC-39A), the historic launch pad once used for Apollo and Space Shuttle missions.

Dual environmental reviews

At the same time, the US Space Force is overseeing a similar EIS for SpaceX’s proposal to take over a launch pad at Cape Canaveral Space Force Station, a few miles south of LC-39A. This launch pad, designated Space Launch Complex 37 (SLC-37), is available for use after United Launch Alliance’s last Delta rocket lifted off there in April.

On the one hand, these environmental reviews often take a while and could cloud Elon Musk’s goal of having Starship launch sites in Florida ready for service by the end of 2025. “A couple of years would not be a surprise,” said George Nield, an aerospace industry consultant and former head of the FAA’s Office of Commercial Space Transportation.

Another way to look at the recent FAA and Space Force announcements of pending environmental reviews is that SpaceX finally appears to be cementing its plans to launch Starship from Florida. These plans have changed quite a bit in the last five years.

The environmental reviews will culminate in a decision on whether to approve SpaceX’s proposals for Starship launches at LC-39A and SLC-37. The FAA will then go through a separate licensing process, similar to the framework used to license the first three Starship test launches from South Texas.

NASA has contracts with SpaceX worth more than $4 billion to develop a human-rated version of Starship to land astronauts on the Moon on the first two Artemis lunar landing flights later this decade. To do that, SpaceX must stage a fuel depot in low-Earth orbit to refuel the Starship lunar lander before it heads for the Moon. It will take a series of Starship tanker flights—perhaps 10 to 15—to fill the depot with cryogenic propellants.

Launching that many Starships over the course of a month or two will require SpaceX to alternate between at least two launch pads. NASA and SpaceX officials say the best way to do this is by launching Starships from one pad in Texas and another in Florida.

Earlier this week, Ars spoke with Lisa Watson-Morgan, who manages NASA’s human-rated lunar lander program. She was at Kennedy Space Center this week for briefings on the Starship lander and a competing lander from Blue Origin. One of the topics, she said, was the FAA’s new environmental review before Starship can launch from LC-39A.

“I would say we’re doing all we can to pull the schedule to where it needs to be, and we are working with SpaceX to make sure that their timeline, the EIS timeline, and NASA’s all work in parallel as much as we can to achieve our objectives,” she said. “When you’re writing it down on paper just as it is, it looks like there could be some tight areas, but I would say we’re collectively working through it.”

Officially, SpaceX plans to perform a dress rehearsal for the Starship lunar landing in late 2025. This will be a full demonstration, with refueling missions, an uncrewed landing of Starship on the lunar surface, then a takeoff from the Moon, before NASA commits to putting people on Starship on the Artemis III mission, currently slated for September 2026.

So you can see that schedules are already tight for the Starship lunar landing demonstration if SpaceX activates launch pads in Florida late next year.

We take a stab at decoding SpaceX’s ever-changing plans for Starship in Florida Read More »

report:-boeing-may-reacquire-spirit-at-higher-price-despite-hating-optics

Report: Boeing may reacquire Spirit at higher price despite hating optics

Still up in the air —

Spirit was initially spun out from Boeing Commercial Airplanes in 2005.

Report: Boeing may reacquire Spirit at higher price despite hating optics

Amid safety scandals involving “many loose bolts” and widespread problems with Boeing’s 737 Max 9s, Boeing is apparently considering buying back Spirit AeroSystems, the key supplier behind some of Boeing’s current manufacturing problems, sources told The Wall Street Journal.

Spirit was initially spun out from Boeing Commercial Airplanes in 2005, and Boeing had planned to keep it that way. Last year, Boeing CEO Dave Calhoun sought to dispel rumors that Boeing might reacquire Spirit as federal regulators launched investigations into both companies. But now Calhoun appears to be “softening that stance,” the WSJ reported.

According to the WSJ’s sources, no deal has formed yet, but Spirit has initiated talks with Boeing and “hired bankers to explore strategic options.” Sources also confirmed that Spirit is weighing whether to sell its operations in Ireland, which manufactures parts for Boeing rival Airbus.

Perhaps paving the way for these talks, Spirit replaced its CEO last fall with a former Boeing executive, Patrick Shanahan. In a press release noting that Spirit relies “on Boeing for a significant portion of our revenues,” Spirit touted Shanahan as a “seasoned executive” with 31 years at Boeing, and Shanahan promised to “stabilize” Spirit’s operations.

If Boeing reacquired Spirit, it might help reduce backlash over Boeing outsourcing manufacturing of its planes, but it likely wouldn’t help Boeing escape the ongoing scrutiny. While the WSJ reported that “Spirit parts frequently arrive” at the Boeing factory “with defects,” it was “a snafu at Boeing’s factory” that led Alaska Airlines to ground 65 Boeing aircraft over safety concerns after a mid-aircraft door detached mid-flight, endangering passengers and crew.

Sources later revealed that it was Boeing employees who failed to put bolts back in when they reinstalled a door plug, reportedly causing the malfunction that forced Alaska Airlines to make an emergency landing. As a result, Boeing withdrew from a safety exemption that it had requested “to prematurely allow the 737 Max 7 to enter commercial service.” At that time, US Sen. Tammy Duckworth (D-Ill.) accused Boeing of a “bold-face attempt to put profits over the safety of the flying public.”

Purchasing Spirit would appear to be a last resort for Boeing, the WSJ reported, noting that so far, “Boeing has done everything short of acquiring Spirit in an effort to gain control over the supplier.”

But Reuters confirmed the WSJ’s report with an industry source, so it seems like perhaps Boeing increasingly feels it has no other options left despite working closely with Shanahan for the past few months to keep Spirit’s troubles from impacting Boeing’s bottom line. One industry source told Reuters that in the time since Boeing spun off Spirit, “the optics of buying at a higher price were among the factors that discouraged such a move.”

For Spirit, which attributes nearly two-thirds of its revenues to Boeing, the WSJ reported, being brought back into the Boeing fold could be the only way to survive these turbulent times. Currently valued at about $3.3 billion, Spirit has struggled for months to shore up a commercial agreement with Airbus and notably failed to stabilize after receiving a “$100 million cash infusion from Boeing” last year, the WSJ reported.

But for Boeing, the obvious downside of the purchase would be taking on Spirit’s mess at the same time Boeing is trying to clean up its own image.

Report: Boeing may reacquire Spirit at higher price despite hating optics Read More »