A SpaceX Falcon 9 Will Blow Up Very Soon, And That’s OK

January 16, 2020 by Tom Nardi 27 Comments

They say you can’t make an omelette without breaking a few eggs, and there are few fields where this idiom is better exemplified than rocketry. It’s a forgone conclusion that when you develop a new booster, at least a few test articles are going to be destroyed in the process. In fact, some argue that a program that doesn’t push the hardware to the breaking point is a program that’s not testing aggressively enough.

Which is why, assuming everything goes according to plan, SpaceX will be obliterating one of their Falcon 9 boosters a little after 8:00 AM EST on Saturday morning. The event will be broadcast live via the Internet, and thanks to the roughly 70% propellant load it will be carrying at the moment of its destruction, it should prove to be quite a show.

This might seem like an odd way to spend $62 million, but for SpaceX, it’s worth it to know that the Crew Dragon Launch Abort System (LES) will work under actual flight conditions. The LES has already been successfully tested once, but that was on the ground and from a standstill. It allowed engineers to see how the system would behave should an abort occur while the rocket was still on the pad, but as the loss of the Soyuz MS-10 dramatically demonstrated, astronauts may need to make a timely exit from a rocket that’s already well on the way to space.

In an actual emergency, the crewed spacecraft will very likely be speeding away from a violent explosion and rapidly expanding cloud of shrapnel. The complete destruction of the Falcon 9 that will be carrying the Crew Dragon during Saturday’s test will serve to create the same sort of conditions the spacecraft will need to survive if the LES has any hope of bringing the crew home safely. So even if there was some way to prevent the booster from breaking up during the test, it’s more useful from an engineering standpoint to destroy it.

Of course, that only explains why the Falcon 9 will be destroyed during this test. But exactly how this properly functioning booster will find itself being ripped to pieces high over the Atlantic Ocean in a matter of seconds is an equally interesting question.

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Starlink Satellites Posing Issues For Astronomers

November 20, 2019 by Lewin Day 118 Comments

Spotting satellites from the ground is a popular pastime among amateur astronomers. Typically, the ISS and Iridium satellites have been common sightings, with their orbits and design causing them to appear sufficiently bright in the sky. More recently, SpaceX’s mass launches of Starlink satellites have been drawing attention for the wrong reasons.

A capture from the Cerro Telolo observatory, showing the many Starlink satellite tracks spoiling the exposure.

Starlink is a project run by SpaceX to provide internet via satellite, using a variety of techniques to keep latency down and bandwidth high. There’s talk of inter-satellite laser communications, autonomous obstacle avoidance, and special designs to limit the amount of space junk created. We’ve covered the technology in a comprehensive post earlier this year.

The Starlink craft have long worried astronomers, who rely on a dark and unobstructed view of the sky to carry out their work. There are now large numbers of the satellites in relatively low orbits, and the craft have a high albedo, meaning they reflect a significant amount of the sunlight that hits them. With the craft also launching in a closely-packed train formation, there have already been impacts on research operations.

There is some hope that as the craft move to higher orbits when they enter service, this problem will be reduced. SpaceX are also reportedly considering modifications to the design to reduce albedo, helping to keep the astronomy community onside. Regardless, with plans on the table to launch anywhere from 12,000 to 42,000 satellites, it’s likely this isn’t the last we’ll hear about the issue.

Developing Guidelines For Sustainable Spaceflight

October 22, 2019 by Tom Nardi 18 Comments

In the early days of spaceflight, when only the governments of the United States and the Soviet Union had the ability to put an object into orbit, even the most fanciful of futurists would have had a hard time believing that commercial entities would one day be launching sixty satellites at a time. What once seemed like an infinite expanse above our heads is now starting to look quite a bit smaller, and it’s only going to get more crowded as time goes on. SpaceX is gearing up to launch nearly 12,000 individual satellites for their Starlink network by the mid-2020s, and that’s just one of the “mega constellations” currently in the works.

Just some of the objects in orbit around the Earth

It might seem like overcrowding of Earth orbit is a concern for the distant future, but one needs only look at recent events to see the first hints of trouble. On September 2nd, the European Space Agency announced that one of its research spacecraft had to perform an evasive maneuver due to a higher than acceptable risk of colliding with one of the first-generation Starlink satellites. Just two weeks later, Bigelow Aerospace were informed by the United States Air Force that there was a 1 in 20 chance that a defunct Russian Cosmos 1300 satellite would strike their Genesis II space station prototype.

A collision between two satellites in orbit is almost certain to be catastrophic, ending with both spacecraft either completely destroyed or severely damaged. But in the worst case, the relative velocity between the vehicles can be so great that the impact generates thousands of individual fragments. The resulting cloud of shrapnel can circle the Earth for years or even decades, threatening to tear apart any spacecraft unlucky enough to pass by.

Fortunately avoiding these collisions shouldn’t be difficult, assuming everyone can get on the same page before it’s too late. The recently formed Space Safety Coalition (SSC) is made up of more than twenty aerospace companies that realize the importance of taking proactive steps to ensure humanity retains the unfettered access to outer space by establishing some common “Rules of the Road” for future spacecraft.

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Hackaday Links: October 6, 2019

October 6, 2019 by Dan Maloney 15 Comments

“If you or someone you love has been exposed to questionable quality electrolytic capacitors, you could be entitled to financial compensation.” Perhaps that’s not exactly the pitch behind this class action lawsuit against capacitor manufacturers, but it might as well be. The suit claims that the defendants, a group of capacitor manufacturers that includes Nichicon, Matsuo, ELNA, and Panasonic, “engaged in an unlawful conspiracy to fix, raise, maintain, or stabilize the prices of Capacitors.” Translation: if you bought capacitors between 2002 and 2014 from a distributor, you paid too much for them. The suit aims to recover a bunch of money from the defendants and divide it up between all the class members, so make sure you go back through all your receipts from Mouser and DigiKey over the last 17 years so you can file a claim that could be worth several dozen cents.

When are people going to learn that posting pictures of their illegal activities online is an Official Bad Idea? One SpaceX fan earned a night in jail after posting selfies he took with Starhopper, the SpaceX test article currently residing at Elon Musk’s would-be spaceport at Boca Chica, Texas. JB Wagoner, a SpaceX super-fan, made the pilgrimage from California to Texas — in his Tesla of course — to see the recent Starship Mark 1 unveiling, and decided to take a side trip to see the Starhopper. He parked at a beach, climbed a dune, and was able to walk right up to Starhopper and go selfie-crazy. After posting the pictures on Facebook, he was arrested, interviewed by Homeland Security, charged with criminal trespass, and thrown in a cell overnight. Wagoner has since been bonded out, but the charges might not stick, since Texas trespassing law requires clear signage or verbal notification of trespass, neither of which Wagoner encountered. SpaceX had even let the fence between the beach and the Starhopper collapse, so Wagoner seems to have had no way of knowing he was trespassing. Still, posting the pictures online was probably asking for trouble.

As satire and dark comedy, the 1987 cyberpunk classic RoboCop can’t be beat. But it also managed to accurately foreshadow a lot of what was to come in the world in terms of technology. No, we don’t have cyborg law enforcement — yet — but we do have something predicted by one throwaway scene: robotic realtors. In the movie, kiosks were set up around Murphy’s old house to extol the various virtues of living there, which ended up triggering the cyborg and starting the film’s climactic rampage. The real-life robotic realtor is a little more flexible, more like a telepresence robot — described aptly as “a Segway with an iPad on top.” The robotic realtor is not autonomous; it only lets a remote realtor interact with potential homebuyers without having to travel to multiple homes. It seems a little gimmicky to us, but the robots are reported to have made 25 sales in their first year on the job.

We’ve been seeing a lot of cheap resin printers these days, enough to make us want to jump into the market and start playing with them. But the cheap ones are all cheap for the same reason — they’re so dang small! They all use LCD screens from phones to mask off the UV light used to cure the resin, and the resulting print volume is tiny. Clem Mayer from MayerMakes has bigger ideas, though: he wants to make a giant resin printer using an LCD monitor as the mask. It’s not as simple as using a bigger screen, though; the film used between the screen and the resin, a fluoropolymer film called FEP, gets deformed when used on larger screens. So Clem is looking at a new built-plate interface that floats the resin on a layer of denser, immiscible liquid. It’s an interesting idea that is still clearly in the proof-of-concept phase, but we look forward to seeing what progress Clem makes.

Rocket Lab Sets Their Sights On Rapid Reusability

August 22, 2019 by Tom Nardi 24 Comments

Not so very long ago, orbital rockets simply didn’t get reused. After their propellants were expended on the journey to orbit, they petered out and fell back down into the ocean where they were obliterated on impact. Rockets were disposable because, as far as anyone could tell, building another one was cheaper and easier than trying to reuse them. The Space Shuttle had proved that reuse of a spacecraft and its booster was possible, but the promised benefits of reduced cost and higher launch cadence never materialized. If anything, the Space Shuttle was often considered proof that reusability made more sense on paper than it did in the real-world.

Rocket Lab CEO Peter Beck with Electron rocket

But that was before SpaceX started routinely landing and reflying the first stage of their Falcon 9 booster. Nobody outside the company really knows how much money is being saved by reuse, but there’s no denying the turn-around time from landing to reflight is getting progressively shorter. Moreover, by performing up to three flights on the same booster, SpaceX is demonstrating a launch cadence that is simply unmatched in the industry.

So it should come as no surprise to find that other launch providers are feeling the pressure to develop their own reusability programs. The latest to announce their intent to recover and eventually refly their vehicle is Rocket Lab, despite CEO Peter Beck’s admission that he was originally against the idea. He’s certainly changed his tune. With data collected over the last several flights the company now believes they have a reusability plan that’s compatible with the unique limitations of their diminutive Electron launch vehicle.

According to Beck, the goal isn’t necessarily to save money. During his presentation at the Small Satellite Conference in Utah, he explained that what they’re really going after is an increase in flight frequency. Right now they can build and fly an Electron every month, and while they eventually hope to produce a rocket a week, even a single reuse per core would have a huge impact on their annual launch capability:

If we can get these systems up on orbit quickly and reliably and frequently, we can innovate a lot more and create a lot more opportunities. So launch frequency is really the main driver for why Electron is going reusable. In time, hopefully we can obviously reduce prices as well. But the fundamental reason we’re doing this is launch frequency. Even if I can get the stage back once, I’ve effectively doubled my production ratio.

But, there’s a catch. Electron is too small to support the addition of landing legs and doesn’t have the excess propellants to use its engines during descent. Put simply, the tiny rocket is incapable of landing itself. So Rocket Lab believes the only way to recover the Electron is by snatching it out of the air before it gets to the ground.

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SpaceX Clips Dragon’s Wings After Investigation

August 5, 2019 by Tom Nardi 120 Comments

When the SpaceX Dragon spacecraft reached orbit for the first time in 2010, it was a historic achievement. But to qualify for NASA’s Commercial Orbital Transportation Services (COTS) program, the capsule also needed to demonstrate that it could return safely to Earth. Its predecessor, the Space Shuttle, had wings that let it glide home and land like a plane. But in returning to the classic capsule design of earlier spacecraft, SpaceX was forced to rely on a technique not used by American spacecraft since the 1970s: parachutes and an ocean splashdown.

The Dragon’s descent under parachute, splashdown, and subsequent successful recovery paved the way for SpaceX to begin a series of resupply missions to the International Space Station that continue to this day. But not everyone at SpaceX was satisfied with their 21st century spacecraft having to perform such an anachronistic landing. At a post-mission press conference, CEO Elon Musk told those in attendance that eventually the Dragon would be able to make a pinpoint touchdown using thrusters and deployable landing gear:

The architecture that you observed today is obviously similar to what was employed in the Apollo era, but the next generation Dragon, the Crew Dragon, we’re actually going to be aiming for a propulsive landing with gear. We’ll still have the parachutes as a backup, but it’s going to be a precision landing, you could literally land on something the size of a helipad propulsively with gear, refuel, and take off again.

But just shy of a decade later, the violent explosion of the first space worthy Crew Dragon has become the final nail in the coffin for Elon’s dream of manned space capsules landing like helicopters. In truth, the future of this particular capability was already looking quite dim given NASA’s preference for a more pragmatic approach to returning their astronauts from space. But Crew Dragon design changes slated to be implemented in light of findings made during the accident report will all but completely remove the possibility of Dragon ever performing a propulsive landing.

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New Space Abort Systems Go Back To The Future

July 15, 2019 by Tom Nardi 26 Comments

Throughout the history of America’s human spaceflight program, there’s been an alternating pattern in regards to abort systems. From Alan Shepard’s first flight in 1961 on, every Mercury capsule was equipped with a Launch Escape System (LES) tower that could pull the spacecraft away from a malfunctioning rocket. But by the first operational flight of the Gemini program in 1965, the LES tower had been deleted in favor of ejection seats. Just three years later, the LES tower returned for the first manned flight of the Apollo program.

With the Space Shuttle, things got more complicated. There was no safe way to separate the Orbiter from the rest of the stack, so when Columbia made its first test flight in 1981, NASA returned again to ejection seats, this time pulled from an SR-71 Blackbird. But once flight tests were complete, the ejector seats were removed; leaving Columbia and all subsequent Orbiters without any form of LES. At the time, NASA believed the Space Shuttle was so reliable that there was no need for an emergency escape system.

It took the loss of Challenger and her crew in 1986 to prove NASA had made a grave error in judgment, but by then, it was too late. Changes were made to the Shuttle in the wake of the accident investigation, but escape during powered flight was still impossible. While a LES would not have saved the crew of Columbia in 2003, another seven lives lost aboard the fundamentally flawed Orbiter played a large part in President George W. Bush’s decision to begin winding down the Shuttle program.

In the post-Shuttle era, NASA has made it clear that maintaining abort capability from liftoff to orbital insertion is a critical requirement. Their own Orion spacecraft has this ability, and they demand the same from commercial partners such as SpaceX and Boeing. But while all three vehicles are absolutely bristling with high-tech wizardry, their abort systems are not far removed from what we were using in the 1960’s.

Let’s take a look at the Launch Escape Systems for America’s next three capsules, and see where historical experience helped guide the design of these state-of-the-art spacecraft.

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