After extensive troubleshooting and recent tests designed to replicate the issues with Boeing’s Starliner spacecraft, Boeing and NASA Identify Starliner Issues, Astronauts Await Next Steps officials still cannot set a return date for the spacecraft’s inaugural crewed test flight. However, engineers have made progress in pinpointing the causes of problems encountered during the spacecraft’s first leg, such as helium leaks and malfunctioning thrusters on the way to the International Space Station.
These insights come after weeks of investigation by Boeing and NASA, with additional tests planned for the weekend to further clarify the issues. Mark Nappi, Boeing’s Commercial Crew Program manager, noted that these tests aim to provide a comprehensive understanding of the problems.
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Engineers in New Mexico conducted over 1,000 test firings of the spacecraft’s thrusters to simulate their operation. This testing helped recreate the issues observed during the flight and identified that excessive heat in the thrusters might be causing Teflon seals to bulge and restrict propellant flow. Nappi stated that this progress has increased confidence in the spacecraft’s ability to safely undock and return.
The findings led Boeing and NASA to scrap plans for allowing astronauts to manually control the Starliner spacecraft during its return journey, as was done briefly on the trip to the ISS. Steve Stich, NASA’s Commercial Crew Program manager, noted that manual maneuvers had stressed the thrusters.
Officials have not confirmed if the same Starliner spacecraft that carried astronauts Butch Wilmore and Suni Williams to the ISS will be used for their return. While there is a strong desire to complete the mission with Starliner, Stich mentioned that NASA has contingency plans if the spacecraft is not cleared for the return trip. He emphasized the need to review all thruster data with the Starliner mission management team.
Nappi expressed confidence in the spacecraft’s ability to safely return the crew. Williams and Wilmore arrived at the ISS on June 6 for a mission expected to last about a week, and as of Thursday, they have been in space for roughly 50 days. NASA has indicated that Starliner can remain in space for up to 90 days.
Further Testing for the Starliner Spacecraft
Separately, engineers are making progress in understanding the helium leaks that affected the first part of Starliner’s journey. Boeing and NASA will revisit this issue with additional testing in space this weekend, which will involve firing 27 of the spacecraft’s thrusters while it remains docked at the ISS.
Ground tests of a Starliner service module in White Sands, New Mexico, have suggested that the leaks might be due to seals degrading from exposure to propellant vapor. Nappi indicated that replacing these seals with more resistant materials could address the problem for future missions.
The next step is to assess whether the leaks on the spacecraft in space have worsened during its time at the ISS. The ground-based module’s long-term exposure to propellant provides insight into potential seal degradation.
This ongoing investigation into helium leaks is a major reason why NASA and Boeing cannot yet set a return date for astronauts Williams and Wilmore or confirm if the Starliner is ready to bring them home. “Understanding the helium leaks and their stability is crucial,” said Stich, noting that they will review plans for Starliner’s undocking, which could occur as early as late next week.
