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SpaceX's in-flight rocket engine failure threatens NASA astronaut launch debut

Falcon 9 punches through Max Q - peak aerodynamic stress - during its Starlink L6 launch. The booster did not survive the mission. (Richard Angle)

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An in-flight rocket engine failure during SpaceX’s March 18th Starlink launch could pose a threat to the company’s imminent NASA astronaut launch debut according to a statement provided by the space agency yesterday.

SpaceX and NASA are currently working around the clock to prepare a Falcon 9 rocket and Crew Dragon spacecraft for the company’s inaugural astronaut launch, a flight known as Demonstration Mission 2 (Demo-2/DM-2). All launch vehicle and spacecraft hardware – including booster B1058, an expendable upper stage, a spacecraft trunk, and the Crew Dragon capsule itself – are already believed to be at SpaceX’s Florida launch and processing facilities.

Prior to March 18th, the biggest gating items were believed to be a few final parachute tests and a whole lot of paperwork and reviews, as well as some important but less showstopping astronaut training. Unfortunately, SpaceX has suffered two unforeseen issues of varying severity in the last few days, both of which are now all but guaranteed to impact Crew Dragon’s astronaut launch debut schedule.

“According to the CCtCap contracts, SpaceX is required to make available to NASA all data and resulting reports. SpaceX, with NASA’s concurrence, would need to implement any corrective actions found during the investigation related to its commercial crew work prior to its flight test with astronauts to the International Space Station. NASA and SpaceX are holding the current mid-to-late May launch timeframe, and would adjust the date based on review of the data, if appropriate.”

NASA — March 25th, 2020

B1048 lifted off for the fifth and final time on March 18th, 2020. (Richard Angle)

On March 18th, less than three minutes after liftoff and shortly before stage separation was scheduled, Falcon 9 booster B1048 – on its historic fifth launch attempt – suffered an engine failure visible on SpaceX’s official webcast. By all appearances, Falcon 9’s autonomous flight computer accounted for the engine’s failure, shutdown, and the resultant loss of thrust by burning B1048’s eight remaining engines for several seconds longer than planned.

Falcon 9 B1048 is pictured during launch, one frame (~0.05s) before it suffered an engine failure. (SpaceX)
The first frame of the off-nominal event. The extremely unusual flare is very likely one of Falcon 9’s nine Merlin 1D engines exploding during flight. (SpaceX)

While that extra few seconds of burn time likely ensured that the rocket’s upper stage was able to make it to the correct orbit after stage separation, roughly five minutes after B1048’s extremely rapid engine failure, contact was lost. For the first time ever, there were no landing burn-related call-outs from SpaceX launch operators, the first sign that something was seriously wrong. A few minutes later, SpaceX’s webcast hosts acknowledged that the booster had been lost, perhaps lacking the propellant it needed to attempt a landing.

For reference, Merlin 1D engines likely consume some ~270 kg (600 lb) of fuel each second. Falcon 9’s landing propellant reserves are believed to be on the order of 50+ metric tons (110,000 lb). Excluding the failed engine, eight Merlin 1Ds burning at full thrust for an additional 5 seconds would consume 20% of the propellant needed for landing; 10 seconds and it would use 40%.

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The anomaly was Merlin 1D engine’s first in-flight failure ever. The 2012 failure of one of an original Falcon 9 V1.0’s rocket’s nine Merlin 1C engines is SpaceX’s only other in-flight failure.

It’s likely that B1048’s engine failure was primarily related to the fact that the booster was SpaceX’s pathfinder for a fifth-flight reusability milestone, making it the most reused rocket booster ever launched. NASA currently requires all of its Crew Dragon missions to launch on new Falcon 9 rockets, hopefully mitigating direct corollaries between the Starlink L6 anomaly and astronaut launches. Regardless, the space agency says that the company will now have to complete its internal failure review and implement necessary hardware, software, or rule changes before it’s allowed to launch NASA astronauts.

In a major twist, NASA has effectively confirmed that SpaceX will become the first private company in history to launch astronauts into orbit. (SpaceX)
Technicians prepare SpaceX’s Crew Dragon Demo-2 spacecraft for its historic launch debut in February 2020. (SpaceX)

That investigation could take a matter of weeks, possibly even less, but it’s entirely possible that it could take months – let alone fixing the problems that allowed the in-flight Merlin 1D engine failure to happen in the first place. Ultimately, it will almost certainly make even the first flights of Falcon 9 and Heavy rocket boosters safer, but it could substantially delay SpaceX’s Demo-2 astronaut launch debut. Still targeted no earlier than (NET) mid-to-late May 2020, it’s safe to say that it’s reasonable to expect that schedule to slip over the next 4-6 weeks. Stay tuned for updates.

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 CEO Elon Musk sends rivals dire warning about Full Self-Driving

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Credit: Tesla

Tesla CEO Elon Musk revealed today on the social media platform X that legacy automakers, such as Ford, General Motors, and Stellantis, do not want to license the company’s Full Self-Driving suite, at least not without a long list of their own terms.

“I’ve tried to warn them and even offered to license Tesla FSD, but they don’t want it! Crazy,” Musk said on X. “When legacy auto does occasionally reach out, they tepidly discuss implementing FSD for a tiny program in 5 years with unworkable requirements for Tesla, so pointless.”

Musk made the remark in response to a note we wrote about earlier today from Melius Research, in which analyst Rob Wertheimer said, “Our point is not that Tesla is at risk, it’s that everybody else is,” in terms of autonomy and self-driving development.

Wertheimer believes there are hundreds of billions of dollars in value headed toward Tesla’s way because of its prowess with FSD.

A few years ago, Musk first remarked that Tesla was in early talks with one legacy automaker regarding licensing Full Self-Driving for its vehicles. Tesla never confirmed which company it was, but given Musk’s ongoing talks with Ford CEO Jim Farley at the time, it seemed the Detroit-based automaker was the likely suspect.

Tesla’s Elon Musk reiterates FSD licensing offer for other automakers

Ford has been perhaps the most aggressive legacy automaker in terms of its EV efforts, but it recently scaled back its electric offensive due to profitability issues and weak demand. It simply was not making enough vehicles, nor selling the volume needed to turn a profit.

Musk truly believes that many of the companies that turn their backs on FSD now will suffer in the future, especially considering the increased chance it could be a parallel to what has happened with EV efforts for many of these companies.

Unfortunately, they got started too late and are now playing catch-up with Tesla, XPeng, BYD, and the other dominating forces in EVs across the globe.

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Tesla backtracks on strange Nav feature after numerous complaints

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Credit: Tesla

Tesla is backtracking on a strange adjustment it made to its in-car Navigation feature after numerous complaints from owners convinced the company to make a change.

Tesla’s in-car Navigation is catered to its vehicles, as it routes Supercharging stops and preps your vehicle for charging with preconditioning. It is also very intuitive, and features other things like weather radar and a detailed map outlining points of interest.

However, a recent change to the Navigation by Tesla did not go unnoticed, and owners were really upset about it.

Tesla’s Navigation gets huge improvement with simple update

For trips that required multiple Supercharger stops, Tesla decided to implement a naming change, which did not show the city or state of each charging stop. Instead, it just showed the business where the Supercharger was located, giving many owners an unwelcome surprise.

However, Tesla’s Director of Supercharging, Max de Zegher, admitted the update was a “big mistake on our end,” and made a change that rolled out within 24 hours:

The lack of a name for the city where a Supercharging stop would be made caused some confusion for owners in the short term. Some drivers argued that it was more difficult to make stops at some familiar locations that were special to them. Others were not too keen on not knowing where they were going to be along their trip.

Tesla was quick to scramble to resolve this issue, and it did a great job of rolling it out in an expedited manner, as de Zegher said that most in-car touch screens would notice the fix within one day of the change being rolled out.

Additionally, there will be even more improvements in December, as Tesla plans to show the common name/amenity below the site name as well, which will give people a better idea of what to expect when they arrive at a Supercharger.

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Dutch regulator RDW confirms Tesla FSD February 2026 target

The regulator emphasized that safety, not public pressure, will decide whether FSD receives authorization for use in Europe.

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The Dutch vehicle authority RDW responded to Tesla’s recent updates about its efforts to bring Full Self-Driving (Supervised) in Europe, confirming that February 2026 remains the target month for Tesla to demonstrate regulatory compliance. 

While acknowledging the tentative schedule with Tesla, the regulator emphasized that safety, not public pressure, will decide whether FSD receives authorization for use in Europe.

RDW confirms 2026 target, warns Feb 2026 timeline is not guaranteed

In its response, which was posted on its official website, the RDW clarified that it does not disclose details about ongoing manufacturer applications due to competitive sensitivity. However, the agency confirmed that both parties have agreed on a February 2026 window during which Tesla is expected to show that FSD (Supervised) can meet required safety and compliance standards. Whether Tesla can satisfy those conditions within the timeline “remains to be seen,” RDW added.

RDW also directly addressed Tesla’s social media request encouraging drivers to contact the regulator to express support. While thanking those who already reached out, RDW asked the public to stop contacting them, noting these messages burden customer-service resources and have no influence on the approval process. 

“In the message on X, Tesla calls on Tesla drivers to thank the RDW and to express their enthusiasm about this planning to us by contacting us. We thank everyone who has already done so, and would like to ask everyone not to contact us about this. It takes up unnecessary time for our customer service. Moreover, this will have no influence on whether or not the planning is met,” the RDW wrote. 

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The RDW shares insights on EU approval requirements

The RDW further outlined how new technology enters the European market when no existing legislation directly covers it. Under EU Regulation 2018/858, a manufacturer may seek an exemption for unregulated features such as advanced driver assistance systems. The process requires a Member State, in this case the Netherlands, to submit a formal request to the European Commission on the manufacturer’s behalf.

Approval then moves to a committee vote. A majority in favor would grant EU-wide authorization, allowing the technology across all Member States. If the vote fails, the exemption is valid only within the Netherlands, and individual countries must decide whether to accept it independently.

Before any exemption request can be filed, Tesla must complete a comprehensive type-approval process with the RDW, including controlled on-road testing. Provided that FSD Supervised passes these regulatory evaluations, the exemption could be submitted for broader EU consideration.

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