Astronauts stranded in space due to multiple issues with Boeing's Starliner — and the window for a return flight is closing

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Astronauts stranded in space due to multiple issues with Boeing's Starliner — and the window for a return flight is closing​


Two NASA astronauts who rode to orbit on Boeing's Starliner are currently stranded in space aboard the International Space Station (ISS) after engineers discovered numerous issues with the Boeing spacecraft. Teams on the ground are now racing to assess Starliner's status.

Astronauts Butch Wilmore and Suni Williams were originally scheduled to return to Earth on June 13 after a week on the ISS, but their stay has been extended for a second time due to the ongoing issues. The astronauts will now return home no sooner than June 26th, according to NASA.

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After years of delays, Boeing's Starliner capsule successfully blasted offon its inaugural crewed flight from Florida's Cape Canaveral Space Force Station at 10:52 a.m. EDT on June 5. But during the 25-hour flight, engineers discovered five separate helium leaks to the spacecraft's thruster system.

Now, to give engineers time to troubleshoot the faults, NASA has announced it will push back the perilous return flight, extending the crew's stay on the space station to at least three weeks.

"We've learned that our helium system is not performing as designed," Mark Nappi, Boeing's Starliner program manager, said at a news conference on June 18. "Albeit manageable, it's still not working like we designed it. So we've got to go figure that out."

The return module of the Starliner spacecraft is currently docked to the ISS's Harmony module as NASA and Boeing engineers assess the vital hardware issues aboard the vessel, including five helium leaks to the system that pressurizes the spacecraft's propulsion system, and five thruster failures to its reaction-control system.

After powering the thrusters up on June 15, engineers found that most of these issues appeared to be at least partially resolved, but their exact causes remain unknown.

However, the Harmony module's limited fuel means Starliner can only stay docked for 45 days, so the window for a safe return flight is narrowing.

The issues are the latest in a long list of setbacks and headaches for Boeing's spacecraft. The company built the Starliner capsule as a part of NASA's Commercial Crew Program, a partnership between the agency and private companies to ferry astronauts into low Earth orbit following the retirement of NASA's space shuttles in 2011. SpaceX's Crew Dragon also came from this initiative and has racked up 12 crewed flights since it began operating in 2020.

But Starliner's first uncrewed test flight in 2019 was scuppered by a software fault that placed it in the wrong orbit, and a second attempt was held back by issues with a fuel valve. After more reviews last year, the company had to fix issues with the capsule's parachutes and remove around a mile (1.6 kilometers) of tape that was found to be flammable.

The current mission is Boeing's third attempt to take the crew to the ISS. The previous two were scrubbed by a vibrating oxygen valve on the United Launch Alliance's Atlas V rocket on which Starliner was mounted (and which was developed by Lockheed Martin) and a computer glitch in a ground launch sequencer, respectively.
 
They're still trying to fix that fucking thing?
If I was one of those astronauts I'd be refusing to leave until they sent up a non Boeing tin can. Soyuz, SpaceX, even that shady ESA thing would be better.

Or rip off a chunk of metal and surf down, a la Dark Star.
NASA has made it clear to them in closed channels that they're going home in a Boeing plane, even if it turns into their tomb.
 
Didn't one of Musk's rockets explode recently? Is SpaceX even in a position to help?
You're confusing Starship test flights (which they know are probably not coming back) with Falcon 9 launches, that have a near perfect record at this point.

Flight 354 back on 7/12 was the first actual failure after 325 consecutive successful launches, and it didn't explode. The second stage failed to relight for it's next burn, resulting in the payload (a stack of Starlink minis) ending up in an unstable orbit and being destroyed on re-entry.

So yes, they could absolutely send up a F9 with an empty Dragon if necessary.
 
So yes, they could absolutely send up a F9 with an empty Dragon if necessary.
They won't any time soon though. Because if they did there won't be a crew for the Starliner anymore. The ISS will decouple it and send it into terminal orbit to burn up. It would be a catastrophe for Boeing and its Government paymasters. So the Starliner crew get to enjoy prison, I mean, being cooped up on the ISS indefinitely while Boeings Pajeets furiously attempt to do the needful.
 
You're confusing Starship test flights (which they know are probably not coming back) with Falcon 9 launches, that have a near perfect record at this point.
No, Primarina was probably thinking of Starlink 9-3 from a couple weeks ago.

SpaceX already found the cause and after some delays launched 3 new Starlink missions in the last 2 days. Crewed missions also wouldn't do the relight of the second stage engine that was done on that one, IIRC.

Engineers and technicians were quickly able to pinpoint the cause of the leak, a crack in a "sense line" for a pressure sensor attached to the vehicle’s liquid oxygen system. "This line cracked due to fatigue caused by high loading from engine vibration and looseness in the clamp that normally constrains the line," the company said in an update published prior to Saturday morning's launch.

This leak excessively cooled the engine, and caused a lower amount of igniter fluid to be available prior to re-lighting the Merlin for its second burn to circularize the rocket's orbit before releasing the Starlink satellites. This caused a hard start of the Merlin engine. Ultimately the satellites were released into a lower orbit, where they burnt up in Earth's atmosphere within days.

The sense line that failed is redundant, SpaceX said. It is not used by the flight safety system, and can be covered by alternate sensors already present on the engine. In the near term, the sense line will be removed from the second stage engine for Falcon 9 launches.

During a news briefing Thursday, SpaceX director Sarah Walker said this sense line was installed based on a customer requirement for another mission. The only difference between this component and other commonly flown sense lines is that it has two connections rather than one, she said. This may have made it a bit more susceptible to vibration, leading to a small crack.
 
This is the sort of story that CNN dreams of running all day, every day. Don Lemon never could find that missing plane that went into the black hole, but maybe he could help these travelers.

But since Boeing is super important to The Narrative, we're just going to ignore that Boeing has fucked up yet again except this time it is two people stuck in OUTER FUCKING SPACE.
 
It is insane. 10 years ago I'd have had no issue flying on a Boeing aircraft and have done so countless times. I will now not fly on anything not fully designed and built by Whites and maybe one or two Japanese. That means nothing newer than a 777-300.
Yes, I will NEVER fly on any Boeing Max aircraft. I am not putting my life in the hands of a company that tried to juice its stock price by going the cheap route in aircraft development instead of designing something new from the ground up.

BTW, Airbus (never been a fan of most of their aircraft for several reasons) has a competing aircraft to the Max and apparently it’s selling very quickly.
 
At the last Starliner press conference, officials tried to clarify reports that the astronauts were "stranded," "trapped" or "stuck" at the space station.

They said the astronauts, who are at ISS living with the rest of the onboard crew, are "comfortable" and have supplies. Mark Nappi, Vice President and Program Manager of the Commercial Crew Program at Boeing said he wished the team had been clearer in their messaging on how loose the timeline was from the beginning.

"I think the only thing we'd do differently... is we would not have been so empathic about an eight-day mission," said Nappi. "We kept saying 'eight-day minimum mission,' I think we all knew it was going to go longer than that ... it's my regret that we didn't just say 'we're gonna stay up there until we get everything done we want to go do.'"

NASA does have contingency options for returning Butch and Sunni to Earth, Stich said, but right now the focus is on finishing up the tasks necessary to do so on Starliner.

That's some next level pr attempt to save the share price. "No one is trapped or stranded, it was always planned to leave them there with no means of safe return". Boeing is just pulling "we only pretended to be retarded" at this point.
 
BTW, Airbus (never been a fan of most of their aircraft for several reasons) has a competing aircraft to the Max and apparently it’s selling very quickly.
The A320neo was the exact reason why the 737 MAX was cooked up in the first place. Boeing was supposed to put out an entirely new narrowbody but they kept dragging their feet since the 737 NG was still doing fine, then Airbus pulls the A320neo out of their asses which proceeds to sell about a gorillion units because it's pretty much the objectively best choice on the market, most alarmingly even American Airlines put in a big order for those dirty Europoor planes to break their tradition of only the finest American aluminum. This made Boeing shit their pants and whip up the MAX on the double to claw back market share, taking the now infamous shortcuts along the way to reduce development time and costs.
 
Update, seems NASA is seriously discussing bringing them back on SpaceX.

Dragon becomes a real option​

One week ago, the last time NASA officials spoke to the media, the agency's program manager for commercial crew, Steve Stich, would not be drawn into discussing what would happen should NASA conclude that Starliner's thrusters were not reliable enough for the return journey to Earth.

“Our prime option is to complete the mission," Stich said one week ago. "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."

For a long time, it seemed almost certain that the astronauts would return to Earth inside Starliner. However, there has been a lot of recent activity at NASA, Boeing, and SpaceX that suggests that Wilmore and Williams could come home aboard a Crew Dragon spacecraft rather than Starliner. Due to the critical importance of this mission, Ars is sharing what we know as of Thursday afternoon.

One informed source said it was greater than a 50-50 chance that the crew would come back on Dragon. Another source said it was significantly more likely than not they would. To be clear, NASA has not made a final decision. This probably will not happen until at least next week. It is likely that Jim Free, NASA's associate administrator, will make the call.

Asked if it was now more likely than not that Starliner's crew would return on Dragon, NASA spokesperson Josh Finch told Ars on Thursday evening, " NASA is evaluating all options for the return of agency astronauts Butch Wilmore and Suni Williams from the International Space Station as safely as possible. No decisions have been made and the agency will continue to provide updates on its planning."

Putting together puzzle pieces​

What follows are some data points that Ars can confidently report based on multiple sources:

  • NASA keeps delaying a decision. A Flight Readiness Review meeting had been scheduled for today, August 1, several days in advance. However, it was canceled. Instead, NASA put out a vague blog update on Thursday stating, "Following the completion of Starliner’s return planning, which is expected to continue into next week, more information will be shared about the agency’s return readiness review preparations and subsequent media briefing." So maybe the meeting will take place next week.
  • NASA issued a $266,678 task award to SpaceX on July 14 for a "special study for emergency response." NASA said this study was not directly related to Starliner's problems, but two sources told Ars it really was. Although the study entailed work on flying more than four crew members home on Crew Dragon—a scenario related to Frank Rubio and the Soyuz MS-22 leaks—it also allowed SpaceX to study flying Dragon home with six passengers, a regular crew complement in addition to Wilmore and Williams.
  • SpaceX has been actively working on a scenario in which two or four astronauts launch on board Crew 9. (A normal crew is four) This mission has a nominal launch date of August 18, but it could well be delayed. SpaceX has already identified flight suits that would fit Wilmore and Williams, allowing them to fly home on the Crew-8 spacecraft (presently docked to the space station) or the Crew-9 vehicle. It is unclear how crews would be assigned to the two Dragon return flights. It is possible, if four astronauts launch on Crew 9, that five people could fly home on each of the two Dragons.
  • Two sources told Ars that in meetings this week at NASA field centers, there have been vigorous discussions about whether or not to fly crew home on Starliner. Multiple groups remain "no" on Starliner as of Wednesday. It is unclear how this will be resolved. Some engineers believe that if there are questions about Starliner, then NASA should opt for the safe course—flying on Crew Dragon, which has safely launched 13 times and landed 12 times.

The toughest of calls​

NASA officials face a difficult decision. Because there is still at least a small risk to flying Starliner in its present condition, the space agency and Boeing have tested the thrusters as thoroughly as possible while the spacecraft is docked to the space station. This testing was intended to "buy down" these risks. But while the data is good, it has not addressed all of NASA's concerns.

So what will the space agency do? Starliner probably could make it back to Earth safely. But there appears to be some reasonable doubt that Starliner will come back safely. If NASA defers to its fallback plan, flying on Dragon, it may spell the end of the Starliner program. During the development and testing of Starliner, the company has already lost $1.6 billion. Reflying a crew test flight mission, which likely would be necessary should Starliner return autonomously, would cost much more. Boeing might opt to cancel Starliner and leave NASA with just a single provider of crew transportation. That would be painful for both NASA and Boeing.

But the alternative—Starliner not coming home safely with the crew inside—is far, far worse. This is the risk-reward decision that Free, Stich, and other NASA officials ultimately must balance in the coming days.
 
'NASA officials face a difficult decision. Because there is still at least a small risk to flying Starliner in its present condition.'

'So what will the space agency do? Starliner probably could make it back to Earth safely. But there appears to be some reasonable doubt that Starliner will come back safely.'


We go from small risk to probably ok to reasonable doubt. Just book the Dragon and stop messing about. DEI really has been a rousing success in aerospace engineering.
 
It gets funnier :story:



However, there is also another surprising reason for the delay—the need to update Starliner’s flight software. Three separate, well-placed sources have confirmed to Ars that the current flight software on board Starliner cannot perform an automated undocking from the space station and entry into Earth’s atmosphere.
It is not clear what change Boeing officials made to the vehicle or its software in the two years prior to the launch of Wilmore and Williams. It is possible that the crew has to manually press an undock button in the spacecraft, or the purely autonomous software was removed from coding on board Starliner to simplify its software package. Regardless, sources described the process to update the software on Starliner as "non-trivial" and "significant," and that it could take up to four weeks.
Somebody possibly has to manually undock it from inside the capulse

Guess they need to draw straws!
 
Somebody possibly has to manually undock it from inside the capulse

Guess they need to draw straws!
Eric Berger is guessing there, but the big takeaway is Boeing's software is fucked and Starliner is going nowhere fast. Bad software was what caused the original uncrewed Starliner to fail to reach the ISS.
 
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