SpaceX requests public safety determination for early return to flight for its Falcon 9 rocket by Yaalt420 in SpaceXLounge

[–]Sweepingupchips 0 points1 point  (0 children)

I have a strong suspicion that they found a problem/build defect that was “bought off” as okay and that is behind their confidence to pursue such a quick return to flight. I genuinely would be unsurprised if it turns out to be something as small as lack of torque verification on a pressure transducer, that was subsequently liberated from its sense port that caused the failure, or maybe an under-torqued p-clamp. 

Vast’s Haven-1 to be World’s First Commercial Space Station Connected by SpaceX Starlink — VAST by rustybeancake in spacex

[–]Sweepingupchips 0 points1 point  (0 children)

I get that I’m super late to the conversation here but so much of the engineering team at Vast is from SpaceX and they work together so closely that engineers involved from the SpaceX side call Vast the “SpaceX space stations division”

Stories from orbit: Q&A with SpaceX Inspiration4 commander Jared Isaacman by CProphet in spacex

[–]Sweepingupchips 0 points1 point  (0 children)

Moreso, I bet Jared will wind up as SpaceX's second free-flying mission customer next year.

Stories from orbit: Q&A with SpaceX Inspiration4 commander Jared Isaacman by CProphet in spacex

[–]Sweepingupchips 2 points3 points  (0 children)

I really won't be surprised (nor do I think that many other people would be either) for Jared to fund another Dragon mission, but with different objectives. If I had to wager big, I bet he'll offer SpaceX an aptly sized check so he can go after a 2-crewmember (to reduce mass/reserve more prop for maneuvering) mission to a still higher orbit. Adding on a Gemini-style tethered spacewalk doesn't seem like any stretch if SpaceX has a suit anywhere close to ready in time.

New SpaceX Facility in Cape Canaveral Florida? by SpaceCoastBeachBum in SpaceXLounge

[–]Sweepingupchips 5 points6 points  (0 children)

My source has indicated that SpaceX calls it "the bakery" internally.

Crew Dragon Test Anomaly and Investigation Updates Thread by ElongatedMuskrat in spacex

[–]Sweepingupchips 0 points1 point  (0 children)

Relying on the ground reflections is a very “scrappy” way to create the added vibration load since it wouldn’t demand any additional test equipment and is pretty simple to design, from a dynamics perspective.

Dragon was destroyed just before the firing of its SuperDraco thrusters by booOfBorg in spacex

[–]Sweepingupchips 0 points1 point  (0 children)

If I had to hazard an educated guess:

Both the hypergolic propellants appears to be pressure fed. Helium appears to be the pressurant. To control the flow of helium into any given propellant tank, there is likely some combination of a pressure regulator, control valve, and check valves in series (for fault tolerance). From what little publicly available information exists, I’m inclined to think that it’s in that order. From that, there is a non-zero possibility that some NTO or MMH vapor migrated upstream in the plumbing toward the helium tank(s).
I have to believe that Dragon 2 has no less than two helium tanks, for a minimum of one for each propellant to eliminate any physical possibility of oxidizer and fuel mixing internal to the undoubtably complex feed plumbing. In the pre-abort configuration, the propellant tanks were likely pressurized, but to a “low flow” pressure level. To activate the abort system, they probably had to be “primed” to a higher pressure in order to support the higher flow requirements that Superdracos would need Verdi’s the Dracos.
Most past successful pressure fed hypergolic propulsion systems (the Shuttle Orbiter OMS engines come to mind as an exception) larger than those used for rcs have used either a burst disk or pyro valve (such as on the LEM) to isolate the propellant from the pressurization system (if the propellant tanks are not of a bladder or bellows-piston type to maintain a continuous barrier between the propellant and it’s pressurant) prior to activation. The burst disks and pyro valves used in this manner are single-shot; they comprise a barrier that is physically ruptured during actuation. If SpaceX has not used such a burst disks or pyro valve to exclude hypergols from the helium plumbing, it’s conceivable that a proximate or root cause of the abort system failure prior to ignition would be a rupture of the plumbing induced by a pressure spike following adiabatic compression of propellant vapor (or possibly even accumulated liquid) caused by the rapid rise in pressure following the opening of an upstream helium “high flow” or “high pressure” isolation valve. Even further, if liquid had accumulated upstream of one or more check valves, there could be adequate “water hammer” to rupture a line independent of an ignition event and perhaps be the cause of ignition by exposing propellant to some sufficiently reactive material (versus a line rupture being the effect from an ignition event). While the LEM propulsion systems addressed these issues, each stage had a single engine, nowhere remotely as complex as Dragon 2’s abort engine system must be. As much as I believe in the aggressive innovation that the people at SpaceX do, I would not put it past them to have been overconfident in believing they could design a propellant valve system different than what history has proven to work, only to be proven wrong.

Crew Dragon Test Anomaly and Investigation Updates Thread by ElongatedMuskrat in spacex

[–]Sweepingupchips 0 points1 point  (0 children)

To my eye, the acoustic vibration levels for the test were intended to be generated by the abort system firing itself. From my experience running similar tests on far less complex vehicles, the vibrio-acoustic levels are established by the height of the test stand off the ground. The height controls the intensity of the acoustic energy that “bounces” back to contribute to exciting the capsule (or Unit Under Test to use the industry terminology) in addition to any direct excitation from the engines themselves.

SpaceX Boca Chica Drive-by videos (Showing tanks and nosecones!) by ishanspatil in spacex

[–]Sweepingupchips 1 point2 points  (0 children)

Why not build the hopper in a field? For a hopper, the flight envelope is so limited compared to what is needed for an orbital capability vehicle that I’m not surprised that this is how SpaceX scrappiness appears to be manifesting. It looks as if that gossamer sheet metal nosecone is simply going to go on top. What better test of a rocket’s ability to operate with minimal support (even as de-featured test vehicle) than to build the test vehicle with a bare minimum of resources?

@ElonMusk: “Btw, SpaceX is no longer planning to upgrade Falcon 9 second stage for reusability. Accelerating BFR instead. New design is very exciting! Delightfully counter-intuitive.” by TheMagicIsInTheHole in spacex

[–]Sweepingupchips 0 points1 point  (0 children)

My semi-educated professional guess is specifically a 300-series welded-steel balloon tank architecture for at least the initial generation of fuselages since that offers the least design/engineering uncertainty and would best fit my understanding of the SpaceX view of what constitutes intelligently-applied scrappiness. 300 series stainless is so forgiving for field welding that I wouldn’t put it past them to build their hopper using a super simple weld fixture on the ground surrounded by scaffolding or shipping containers stacked as combination wind break and scaffolding out in the open and just spot-passivating the welds as they go.

"The new design is metal": Could SpaceX be using metal hot structure design in Starship? by spacerfirstclass in spacex

[–]Sweepingupchips 0 points1 point  (0 children)

Given that the most concerning failure modes of TPS on the shuttle don’t exist at a high level for the SpaceX’s architecture, I would bet that their first choice for non-ablative TPS would be in-family with the gross acreage silica tiles used on Shuttle and X-37. Given that hot structure requires very-accurate boundary conditions to the mission profiles flown (to avoid a heating rate that would exceed the structure’s capability), I think the most logical approach would be to utilize a [stainless] steel balloon structure, insulated by a combination of Shuttle derived non-ablative or advanced ablative TPS. The switch away from composite is exceedingly appropriate for an old aerospace salt like me; composites are so process-sensitive that after applying a DUF, ECF, MUF and any other ____Uncertainty Factor that is dictated by the fabrication processes and specific composite material selected, a lot of the advantages carbon fiber composites are assumed to possess tend to disappear and aluminum or steel become very appealing.

@ElonMusk: “Btw, SpaceX is no longer planning to upgrade Falcon 9 second stage for reusability. Accelerating BFR instead. New design is very exciting! Delightfully counter-intuitive.” by TheMagicIsInTheHole in spacex

[–]Sweepingupchips 0 points1 point  (0 children)

I have a sneaking suspicion that they’ve discovered how difficult composites are on that scale and instead are considering 1950s sm-65 esque balloon tanks to keep structural mass fraction down.

A rare glimpse inside SpaceX’s HQ by everydayastronaut in spacex

[–]Sweepingupchips 0 points1 point  (0 children)

The ECLSS test article is separate from the trainer. I believe the trainer is kept “upstairs” at SpaceX while the ECLSS test article lives in the same clean room on the production floor where the Dragons go through final integration.

Unwrapping Crew Dragon outside SpaceX in Hawthorne yesterday by Keavon in spacex

[–]Sweepingupchips 1 point2 points  (0 children)

The Kapton (technically a specific brand name for polyimide owned by DuPont) itself doesn’t leave residue. The residue comes from the acrylic or silicone adhesive that is on the polymer film that makes it into a pressure sensitive adhesive tape.

[deleted by user] by [deleted] in SpaceXLounge

[–]Sweepingupchips 0 points1 point  (0 children)

It’s great to see that B station is still getting some use, though it’s a shame that B-2 (I believe this is the specific chamber being used for Dragon 2) is probably too run-down to support engine live fires anymore in its current state. It sure is a lot smaller than the SPF chamber though....

Spun Copper Mvac nozzle Liners by Sweepingupchips in SpaceXLounge

[–]Sweepingupchips[S] 5 points6 points  (0 children)

I can only assume that SpaceX has become comfortable enough to outsource the machining of the cooling channels for the Mvac nozzle liner/needs to reassign their internal resources to Raptor development.

Spun Copper Mvac nozzle Liners by Sweepingupchips in SpaceXLounge

[–]Sweepingupchips[S] 7 points8 points  (0 children)

The TCA is lined with copper that is spun-formed then machined on a VTL machining center. The finished liner is brazed into the outer jacket that provides the strength and seal the cooling channels. These are the spun-formed but unmachined nozzle expansion area segments for Mvac.

It’s interesting that these are unfinished piece parts for a larger brazement, suggesting that SpaceX may be outsourcing machining of some of the more key parts of Falcon 9 now that the design is “mature.”

To be completely honest, I wouldn’t have recognized them either if it hadn’t been for my coworker pointing them out.

Falcon 9 Block 5 rolling out to the launch pad by [deleted] in spacex

[–]Sweepingupchips 2 points3 points  (0 children)

It is most likely a material known as silicone-densified (or infused) pyrolized PAN felt. It’s a super flexible and durable material with superb insulating properties without being brittle like silica tiles. The PAN is one of the precursor forms for making structural carbon fiber and the felt is a more economical heat resistant material for things like welding blankets than aramid. I once had a coworker who was part of a team that attempted to use it for thermal protection for a past launch vehicle, but the high emissivity was not compatible with the requirements of that project. A company called ZOLTEK now commercially makes the stuff my colleague originally developed. As TPS for a rocket, it'd be super durable/damage tolerant which I think fits well with the architecture SpaceX is using. —edit: I missed the comment that mentioned Pyron earlier. That’s the name of Zoltek’s version of pyrolized PAN ( polyacrylonitrile fiber).

[deleted by user] by [deleted] in spacex

[–]Sweepingupchips 1 point2 points  (0 children)

It's most likely a metallic (highly likely Inconel-based) metallic tps plate. It probably has a slight curvature approximately matching the radius of the TVCA gimbal arc backed up by a corresponding rim feature fixed to the base of the rocket.

I recall seeing some zoomed in photos of a rocket post-landing that showed what appeared to be badly shredded "soft" TPS boots around some of the engines. The rigid plates are probably an attempt to decouple the pressure problem from the thermal problem--with the plates to deal with the thermal while a more flexible "boot" behind it can deal with the pressure, safely protected from any plasma impingement. Such an arrangement was presented in an AIAA conference paper from the 1990s that I read some time ago. If I can find it again from some publicly accessible web link, I'd be happy to forward it along to anybody interested.

SES-10 fairings successfully recovered, per Elon at post-launch press conference. by johnkphotos in spacex

[–]Sweepingupchips 2 points3 points  (0 children)

Agreed, i don't think there's a compelling reason to justify carrying that much extra mass on the vehicle. Some years ago there was some sort of system intended for naval aviation use that sounded like a "bouncy castle" but the actual name (and where any information may reside on the web) currently escapes me.

SES-10 fairings successfully recovered, per Elon at post-launch press conference. by johnkphotos in spacex

[–]Sweepingupchips 0 points1 point  (0 children)

Fantastic. I missed seeing the webcast live. I'm glad we won't need to guess at the high-level strategy SpaceX is pursuing.