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SpaceX says Crew Dragon capsule exploded due to exotic titanium fire

Crew Dragon tests its SuperDraco-powered launch abort system in 2015. (SpaceX)

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6 years ago

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SpaceX has announced via an official update and conference call the preliminary results of a failure investigation convened immediately after Crew Dragon capsule C201 exploded in the midst of an April 20th static fire test.

Hosted by SpaceX Vice President of Mission Assurance Hans Koenigsmann and NASA Commercial Crew Program manager Kathy Lueders, the call provided some minor additional insight beyond a fairly extensive press release issued just prior. According to the preliminary results from SpaceX’s failure investigation, Crew Dragon’s explosion was unrelated to the spacecraft’s propellant tanks, Draco maneuvering thrusters, or SuperDraco abort engines. Rather, the cause lies in a more exotic and unanticipated chemical/material interaction between a plumbing valve, liquid oxidizer, and a helium-based pressurization system.

When metal burns

According to Hans Koenigsmann, SpaceX is approximately 80% of the way through what is known as the fault tree, essentially meaning that the failure investigation is 80% complete. That additional 20% could certainly throw some curveballs but the SpaceX executive was fairly confident that the results presented on July 15th would be representative of the final conclusion.

The ultimate (likely) cause of Crew Dragon’s extremely energetic and destructive explosion centers around the spacecraft’s extensive SuperDraco/Draco plumbing and its associated pressurization system, which uses helium to keep the pressure-fed engines, propellant tanks, and feed lines around 2400 psi (16.5 megapascals). Necessarily, this method of pressurization means that there is direct contact between the pressurant (helium) and the oxidizer/fuel, thus requiring some sort of valve preventing the pressurized fluid from flowing into the pressurization system.

A detailed view of some of the Draco and SuperDraco-related plumbing used on Crew Dragon – in this case, the capsule that will now fly SpaceX’s In-Flight Abort test. (Pauline Acalin, August 2018)

During flight-proven Crew Dragon capsule C201’s April 20th static fire testing, that is reportedly exactly what happened. Over the course of ground testing, a “check valve” separating the pressurization system and oxidizer leaked what SpaceX described as a “slug” of nitrogen tetroxide oxidizer (NTO) into the helium pressurization lines. Around T-100 milliseconds to a planned ignition of the vehicle’s 8 SuperDraco abort engines, the pressurization system rapidly “initialized” (i.e. quickly pressurized the oxidizer and fuel to operational pressures, ~2400 psi).

To do this, helium is rapidly pushed through a check valve – designed with low-molecular-mass helium in mind – to physically pressurize the propellant systems. Unintentionally, the NTO that leaked ‘upstream’ through that valve effectively was taken along for the ride with the high-pressure burst of helium. In essence, picture that you crash your car, only to discover that your nice, fluffy airbag has accidentally been replaced with a bag of sand, and you might be able to visualize the unintended forces Dragon’s check valve (the metaphorical airbag) was subjected to when a “slug” of dense oxidizer was rammed into it at high speed.

Crew Dragon C201 displays its heat shield after the spacecraft’s first orbital-velocity Earth reentry, March 8th. (NASA/Cory Huston)

In itself, this sort of failure mode is not hugely surprising and SpaceX may have even been aware of some sort of check valve leak(s) and accepted what it believed to be a minor risk in order to continue the test and perhaps examine Dragon’s performance under suboptimal conditions. What SpaceX says it did not realize was just how energetic the reaction between the NTO and the check valve could be. SpaceX’s understanding is that the high-speed slug of dense NTO was traveling so fast and at such a high pressure that, by impacting the titanium check valve, it quite literally broke the valve and may have chemically ignited the metal, thus introducing a slug of burning NTO into the liberated NTO system itself – effectively a match tossed into a powder keg.

It’s unclear if the ignition came from a chemical reaction between titanium (a technically flammable metal similar to magnesium) and NTO, or if the source came from the titanium valve being smashed apart, perhaps quite literally creating a spark as metal debris violently interacted. Either way, the solution – as SpaceX perceives it – is the same: instead of a mechanical check valve (simple but still not 100% passive), the barrier between pressurant and oxidizer (as well as fuel, most likely) will be replaced with something known as a burst disk. According to Koenigsmann, only a handful (~4) of those valves exist and thus need to be replaced by burst disks, a relatively fast and easy fix.

Burst disks are single-use and inherently unreusable, but they are also completely passive and simply do not leak until subjected to a specific amount of pressure. Because they are single-use, they can’t be directly tested prior to flight, limiting some of the in-principle reliability for the sake of an extremely leak-proof barrier.

A test of one of Crew Dragon’s four ‘powerpacks’, featuring two SuperDracos and three Dracos. (SpaceX)

Ultimately, both Koenigsmann and Lueders went out of their way to avoid answering any questions about SpaceX’s Crew Dragon upcoming test and launch schedule and what sort of delays the explosion will ultimately incur. Both individuals were nevertheless upbeat and by the sound of it, delays to Crew Dragon will be far less severe relative to delays caused by a pressure vessel or engine failure. For the time being, NASA has published a tentative target of mid-November 2019 for Crew Dragon’s first crewed launch to the International Space Station, while Lueders and Koenigsmann expressed hope in a 2019 launch but refused to give a specific estimate of the odds of that occurring.

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Eric Ralph is Teslarati's senior spaceflight reporter and has been covering the industry in some capacity for almost half a decade, largely spurred in 2016 by a trip to Mexico to watch Elon Musk reveal SpaceX's plans for Mars in person. Aside from spreading interest and excitement about spaceflight far and wide, his primary goal is to cover humanity's ongoing efforts to expand beyond Earth to the Moon, Mars, and elsewhere.

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Tesla analyst says this common earnings narrative is losing importance

“Numbers are going down next year, but that’s ok because it’s all about autonomy.”

Published

9 hours ago

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October 21, 2025

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(Credit: Tesla)

A Tesla (NASDAQ: TSLA) analyst is doubling down on the idea that one common earnings narrative is losing importance as the company continues to work toward new technologies and projects.

This week, Tesla will report earnings for the third quarter, and one thing people always pay attention to is deliveries. Although Tesla reveals its deliveries for the quarter well before it reports earnings, many investors will look for commentary regarding the company’s strategy for responding to the loss of the $7,500 tax credit.

Tesla has made a few moves already, including a lease deal that takes a substantial amount of money off, launching new Standard models, and cutting up to 23 percent off of lease pricing.

Tesla makes crazy move to spur short-term demand in the U.S.

However, analysts are looking at the company in a different light.

Aligning with the narrative that Tesla is not just a car company and has many different projects, Gene Munster of Deepwater Asset Management believes many investors need to look at another part of the business.

Munster said the delivery figures for Q3, which landed at 497,099, the highest in company history, were padded by customers rushing to showrooms to take advantage of the expiring tax credit.

He believes that deliveries will be more realistic in subsequent quarters, but investors should not worry because the focus on Tesla is not going to be on how many cars it hands over to customers:

“Numbers are going down next year, but that’s ok because it’s all about autonomy.”

Tesla has been working nonstop to roll out a dedicated Robotaxi platform in various cities across the United States, and has already launched in two states: Texas and California.

It has also received regulatory approvals to test driverless Robotaxis in Arizona and Nevada, while seeking permissions in Florida and other states, according to the company’s online job postings.

Munster continued:

“Most people are hyper-focused on the Robotaxi opportunity and not focused as much on FSD.”

While Robotaxi is incredibly important, Tesla’s Full Self-Driving (Supervised) suite is also extremely crucial moving forward, as it sets the stage for the company to roll out a formidable self-driving service.

Tesla rolled out its newest FSD software to more owners last night, and as it expands, the company is gaining valuable data to refine its performance.

Earnings will be reported tomorrow at market close.

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Tesla rolled out a new feature with FSD v14 to fix a major complaint

One of the most crucial cameras for FSD operation is located at the top of the windshield, and some owners have complained about condensation or other debris accumulating here, which impacts FSD’s availability during drives.

Published

10 hours ago

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October 21, 2025

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Credit: The Kilowatts | X

Tesla rolled out a new feature with Full Self-Driving (Supervised) v14.1.3 in an effort to fix a major complaint from owners.

Tesla’s approach to self-driving is significantly different than other companies as it only relies on cameras for operation. Tesla Vision was launched several years ago and completely axed any reliance the suite had on sensors, as CEO Elon Musk’s strategy was unorthodox and went against the grain.

However, it has proven to be effective, as Tesla still operates the most refined semi-autonomous driving suite in the United States.

There are some drawbacks, though, and one of them has to do with the obvious: cameras get dirty and need to be cleaned somewhat regularly.

One of the most crucial cameras for FSD operation is located at the top of the windshield, and some owners have complained about condensation or other debris accumulating here, which impacts FSD’s availability during drives:

Tesla has been working to confront this issue, and in classic fashion, it used a software update to work on resolving it.

With the rollout of Full Self-Driving v14.1.3 and Software Version 2025.32.8.15, Tesla added a new feature that aims to clean the front camera efficiently without relying on the owner to do it manually.

Tesla Full Self-Driving’s new version officially gets a wider rollout

In its release notes for the suite, it said:

“Added automatic narrow field washing to provide rapid and efficient front camera self-cleaning, and optimize aerodynamics wash at higher vehicle speed.”

If the camera starts to have some issues with visibility, the car will automatically clean the front windshield camera to avoid any issues:

This new addition is a small but mighty change considering all things. It is a necessary process to keep things operational and avoid any disruptions in FSD performance. It is also a testament to how much better Tesla vehicles can get with a simple software update.

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Tesla Full Self-Driving’s new version officially gets a wider rollout

So far, v14 has introduced a handful of new features and improvements, but the first versions needed refinement before Tesla made an effort to expand the population. It had issues with a brake stutter, but this has been mostly resolved.

Published

12 hours ago

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October 21, 2025

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Credit: Tesla Europe and Middle East | X

Tesla’s newest Full Self-Driving version is officially rolling out wider to customers outside of the Early Access Program (EAP), in preparation for a total launch of the new v14 suite.

Over the past several weeks, Tesla has been working to refine its new v14 Full Self-Driving (Supervised) in an effort to have it ready for the entire fleet of vehicles in the United States. We are lucky enough to be in the EAP, so we’ve been able to test new features and rollouts first-hand.

So far, v14 has introduced a handful of new features and improvements, but the first versions needed refinement before Tesla made an effort to expand the population. It had issues with a brake stutter, but this has been mostly resolved.

Additionally, the rollout of the new Mad Max Speed Profile has gathered some attention.

Now that Tesla has started rolling out v14.1.3 yesterday to EAP members, the company ultimately decided that it was time to expand the software to more vehicles, as many owners are reporting that they’re receiving it:

Additionally, the suite has started to expand to Model S and Model X vehicles, so this rollout is not exclusive to Model 3 and Model Y:

The only issue with this rollout is that it still appears to be missing the Cybertruck, which Tesla was transparent about earlier this month. Although the company planned to release v14 to Cybertrucks by the end of the month, there has been no hint that this is going to happen.

This is already the third iteration of v14 in the past two weeks, indicating that Tesla is truly addressing the shortcomings of past versions and rolling out updates as quickly as possible.

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