NASA Continues Starliner’s Return to Earth Amid Thruster Troubles

By: Sam Watanuki | Published: Jul 11, 2024

NASA managers have delayed the Starliner crew capsule’s return to Earth to ensure its problematic control thrusters can guide the ship’s crew home safely.

The two astronauts, Butch Wilmore and Suni Williams, were supposed to return weeks ago but remain on the ISS as engineers investigate the thruster issues and helium leaks.

Thruster Problems During Docking

Five of the 28 reaction control thrusters on Starliner’s service module failed during its approach to the ISS in June. The flight software disabled these thrusters due to overheating, although four were later recovered.

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Boeing’s Starliner spacecraft approaching the International Space Station amid black space.

Source: Bob Hines/NASA/Wikimedia Commons

The thruster failures impacted the spacecraft’s handling, but it successfully docked in autopilot mode.

Astronauts’ Confidence Despite Delays

Astronauts Butch Wilmore and Suni Williams expressed confidence in the spacecraft despite the delays. “Human spaceflight is not easy,” Wilmore said, acknowledging the challenges.

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NASA astronauts Suni Williams and Butch Wilmore posing and smiling in front of the Starliner capsule.

Source: NASA/Wikimedia Commons

Both astronauts are prepared to fly the capsule back to Earth if necessary, demonstrating their trust in the Starliner’s capabilities.

Testing and Evaluations at White Sands

NASA and Boeing decided to replicate the overheating issue by testing a Starliner thruster at White Sands, New Mexico. The goal is to simulate the same firing sequences that caused the overheating in orbit.

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A group of many people who are mission managers with NASA, Boeing, and United Launch Alliance during a test flight for the Starliner capsule.

Source: NASA/Wikimedia Commons

Engineers are studying the heating effects and potential damage to improve the thruster system’s reliability.

Thruster Redesign Considerations

Boeing engineers are considering design changes to the Starliner’s service module to prevent future thruster issues.

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A Boeing Starliner test launch seen in progress with clouds of smoke around the launch pad in 2022.

Source: NASA/Joel Kowsky/Wikimedia Commons

The focus is on understanding the heating effects within the thruster housings, or “doghouses,” which exacerbate overheating problems. This redesign aims to enhance the spacecraft’s thermal management.

Helium Leaks and Mitigation Strategies

In addition to thruster problems, Starliner has encountered helium leaks. Mark Nappi, Boeing’s Starliner Program Manager, identified over 30 actions to address these leaks.

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Workers putting together the Starliner capsule in a factory in 2019.

Source: NASA/Wikimedia Commons

Engineers are evaluating the spacecraft’s helium reserves to ensure there’s enough for the return journey and future missions.

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Battery Certification and Mission Timeline

Starliner’s batteries were certified for a 45-day mission, which will be reached on July 20.

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An open Calendar book.

Source: Eric Rothermel

However, it’s expected the spacecraft will stay in orbit beyond this period. NASA aims to return Starliner by mid-August to make way for the next SpaceX crew mission, but no final decisions have been made.

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Safety First: The Importance of Thorough Testing

NASA’s Commercial Crew Program Manager, Steve Stich, emphasized the importance of safety and thorough testing. The goal is to ensure that the thrusters can perform adequately for the deorbit burn.

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An up-close look at the top of Boeing’s Starliner craft seen in the daytime.

Source: NASA/Joel Kowsky/Wikimedia Commons

Stich noted that human spaceflight involves inherent risks, and careful evaluation is crucial before committing to return.

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Collaborative Efforts with SpaceX

The presence of SpaceX’s Crew Dragon on the ISS offers flexibility in crew transportation.

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A photograph of a SpaceX Satellite

Source: Tim Peake / ESA/NASA via Getty Images

This dual-provider approach ensures that ISS crew operations can continue smoothly, even if one spacecraft encounters issues.

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Future Operational Missions at Risk

The delays and technical challenges faced by Starliner may impact its operational missions, initially scheduled for early next year.

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Boeing’s Starliner craft seen on its launchpad in the evening.

Source: NASA/Joel Kowsky/Wikimedia Commons

Engineers need time to resolve the thruster and helium leak issues before the next flight. The first operational mission, Starliner-1, is under scrutiny to ensure all problems are addressed.

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Potential Schedule Adjustments

Stich indicated that the longer the current test flight issues persist, the more likely the first operational mission could be delayed.

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Boeing’s Starliner craft approaching the International Space Station with Earth seen below it.

Source: Bob Hines/NASA/Wikimedia Commons

Engineers are considering replacing seals in the next service module to reduce the risk of helium leaks, aiming for a more reliable and efficient spacecraft for future missions.

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The Road Ahead for Starliner

While the delays are challenging, they are part of advancing human spaceflight. The ongoing tests and evaluations are important for ensuring astronaut safety and mission success.

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Astronauts Sunita Williams and Barry Butch Wilmore in front of the Boeing Starliner craft.

Source: NASA/Kim Shiflett/Wikimedia Commons

NASA and Boeing’s collaborative efforts will pave the way for more reliable space missions, reinforcing the importance of rigorous testing and adaptability in space exploration.

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