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SpaceX Starship prototype in limbo after engine test lights rocket on fire

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The fate of SpaceX’s fourth full-scale Starship prototype appears to be in limbo after a third (seemingly successful) engine ignition test unintentionally caught the rocket on fire.

Now more than 12 hours after Starship SN4 fired up its new Raptor engine, the ~30m (~100 ft) tall, 9m (~30 ft) wide prototype is apparently trapped with one or both of its propellant tanks still partially filled with liquid (or gaseous) methane and/or oxygen. An initial road closure scheduled from noon to 6pm local quickly came and went and SpaceX and Cameron County Texas have since modified the paperwork, extending the closure a full 24 hours. In other words, SpaceX has reason to believe that Starship SN4 may continue to be unsafe (i.e. pressurized) as many as ~30 hours after it technically completed its third static fire test – extremely unusual, to say the least.

There’s only one obvious conclusion to draw. Whether it was something invisible to the public eye or damage related to the off-nominal fire that burned for some 15 minutes after Raptor shut down, SpaceX appears – to some extent – to have lost control of Starship SN4.

At the moment, it’s unclear what is wrong and what SpaceX is attempting to do to resolve the problem. Based on photos of Starship SN4 taken before the fire, there is good news and bad news from what can be publicly ascertained. Controlled from the ground by unprotected wires strung up and down the rocket and connected at its base, the uncontrolled fire that burned in at least two locations around Starship’s aft may have severed some or all of those critical connections.

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Starship SN4’s third successful Raptor test caused a secondary fire that has put the vehicle in a state of limbo. (LabPadre)

That would render Starship – potentially perfectly healthy and operational – almost entirely uncontrollable, while also potentially removing SpaceX’s access to telemetry. In other words, the company may currently have no idea how pressurized all or part of Starship SN4 is and may also have little to no control of some or all of the rocket. For that to be true, Starship SN4 would, however, have to have less than fully redundant control hardware. To perform hops, for example, the ship would need both wired and radio links capable of sending telemetry and receiving commands to remain both on the ground and after liftoff.

It’s possible that Starship SN4 has the necessary hardware installed but that it wasn’t activated for the static fire test (think “Starship will never leave the ground, why would we need to enable wireless controls?”). It’s also possible that the blown pipe and methane leak that appeared to cause the secondary fire damaged crucial propellant management hardware (valves, pumps, etc.) or was just a symptom of an even worse overpressure event that damaged or destroyed multiple such systems.

Given that safety is almost certainly the priority, chances are that some combination of fairly mild hardware failure and telemetry/control loss has left SpaceX with just enough uncertainty that it can’t risk sending technicians to the launch site to inspect the damage and reestablish control. As a result, the only option left is to quite literally sit and wait until it’s once again safe to approach the rocket. Thankfully, at this point, the risk of the mystery problem actually destroying Starship SN4 is very low. If, as it appears, only its methane tank is affected, leaving some unknown quantity of latent liquid methane trapped inside, it’s possible that waiting will actually solve the problem and safe the rocket.

Starship SN4 is pictured a few hours before its ill-fated third static fire test. (NASASpaceflight – bocachicagal)
On a positive note, it appears that the concerning amount of dark smoke created in the first minute or two of the post-test fire was caused by a huge amount of tape/insulation/???? wrapped around part of Starship’s test stand in the hours before its May 19th test attempt.(NASASpaceflight – bocachicagal)

The fact that Starship hasn’t exploded yet strongly implies either that the amount of propellant trapped is minuscule or that the vast majority of SN4’s propellant management systems (including vents) remain functional. Assuming that’s the case, any remaining cryogenic propellant will eventually boil into gas, increasing the pressure inside Starship’s tanks, while those tanks will continue to vent to prevent an explosion or rupture. Eventually, Starship SN4 will be empty once again and SpaceX will be able to approach the rocket to regain control and begin inspections and repairs.

Regardless, after such an unintentionally eventful static fire test, it’s extremely unlikely that SN4 will be ready for its inaugural flight test within the next few days. Stay tuned for updates as SpaceX works to regain control over the fourth full-scale Starship prototype.

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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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SpaceX Starship Flight 13 aborted at Zero and Musk just told us what broke

Four Raptor engines failed to ignite at T-zero, forcing SpaceX to scrub Starship Flight 13 Thursday.

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SpaceX scrubbed the Starship Flight 13 launch attempt Thursday evening at the last possible moment, after four of the Super Heavy booster’s 33 Raptor 3 engines failed to ignite during the startup sequence. The 90-minute window had opened at 6:45 p.m. EDT from Starbase in Boca Chica, Texas, and the countdown had proceeded without issue all day, with more than 11.5 million pounds of liquid methane and liquid oxygen being fully loaded into the rocket before the automated abort triggered. SpaceX’s launch directors posted on X, “Standing down from today’s flight test attempt,” and shut down the livestream shortly after.

Musk confirmed the root cause within hours. “Some of the engines didn’t start, triggering an automatic launch abort,” he wrote on X. “To be confident of a good flight, 2 Raptors will be removed and replaced. Most probable launch timing is early next week.” SpaceX engineers began draining propellant tanks immediately and Booster 20 was rolled back to its hangar for inspection.

SpaceX comes with a slew of changes for Starship Flight 13

 

The timing adds a layer of significance that did not exist during any of the previous 12 Starship flights. This is the first time SpaceX has attempted to launch Starship since the company made its stock market debut in June, listing under ticker SPCX at $135 per share. Public investors are now watching every Starship outcome in real time, and a last-second abort carries more visibility than it would have six months ago.

Flight 13 was designed to be one of the most consequential tests in the program’s history. It was set to carry 20 Starlink V3 satellites, the first operational payload Starship has ever attempted to deploy. Six of those satellites carried external cameras to photograph Starship’s heat shield from the outside during flight, which would act as a self-inspection approach SpaceX has never attempted before. The mission also needed to complete a Raptor engine relight in space, a step SpaceX skipped on Flight 12 in May after losing an engine during ascent. That Flight 12 booster also flipped 90 degrees off course during its boostback burn when five engines failed to reignite.

SpaceX has not announced an official next launch date. Musk’s “early next week” window points to July 21 or 22 at the earliest, pending the engine swap and a return to the pad.

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Elon Musk secretly acquires $1B energy company to power the AI future

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Gage Skidmore, CC BY-SA 4.0 , via Wikimedia Commons

Elon Musk flew under the radar with his recent purchase of a $1 billion energy company, according to Federal Trade Commission (FTC) documents.

Transaction number 202612350 listed Tesla and SpaceX frontman Elon Musk as the acquiring party and CF APR Super Holdings LLC as the seller, with New APR Energy, LLC as the acquired entity. The deal, which closed without public announcement, came to light on May 14.

Analysts inferred the deal’s scale from minority stakeholder disclosures, including one report of a 5 percent interest sold for approximately $50.4 million. Fortress Investment Group had purchased APR’s assets in late 2024, rebranded the operation as New APR Energy, and subsequently transferred ownership to Musk.

APR Energy specializes in rapidly deployable power infrastructure. The company maintains one of the world’s largest fleets of mobile gas and diesel turbines, with more than 1.1 gigawatts of generation capacity. Its modular units, which are often trailer-mounted, enable turnkey installations ranging from 20 MW to over 500 MW.

Elon Musk admits he was ‘clearly wrong’ about Anthropic

APR provides full engineering, procurement, construction, operation, and maintenance services for behind-the-meter power plants, serving everything from data centers, utilities, and industrial clients.

The firm has expanded aggressively to meet surging demand, recently adding turbines and deploying over 100 MW for a major AI hyperscaler. Its solutions bridge critical gaps where grid interconnections face delays of two to five years, according to Yahoo.

The acquisition means something more for Musk. As he continues to expand projects in artificial intelligence, especially xAI, his AI venture, there is a greater need to supply energy-intensive supercomputing clusters, including the Colossus project, with what they need: reliable and high-capacity power.

Ownership of APR provides immediate access to flexible generation assets that can be deployed adjacent to data centers, reducing dependence on a strained infrastructure. It also complements Tesla’s energy storage business, so Musk will be able to pull from his own entities to address the rapid scaling demands of AI training and compute.

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Tesla has to fix a big problem with its old headlights, NHTSA says

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tesla model 3 first generation headlight
Credit: Tesla Asia/Twitter

Tesla had a petition protesting a recall to fix a potential issue with 2017-2023 Model Y and Model 3 vehicles’ headlights was denied, as the National Highway Traffic Safety Administration (NHTSA) disagreed with the company’s opinion of things.

The recall covers approximately 19,917 Model Y and Model 3 vehicles built from 2017 to 2023. Tesla initially submitted a noncompliance report for the headlights on these vehicles on March 15, 2024. Tesla then petitioned for an exemption from the fix, which violated FMVSS No. 108 (40 CFR 571.108), arguing that the “noncompliance is inconsequential as it relates to motor vehicle safety.

The NHTSA disagreed, stating that Tesla’s conclusion that the headlights do not increase any risk was not an opinion it shared. The agency said it disagreed with Tesla’s assumption that glare is not increased to surrounding traffic. This issue could be highlighted even more in certain weather conditions.

Tesla will be required to remedy the issue, the NHTSA ruled:

“In consideration of the foregoing, NHTSA has decided that Tesla has not met its burden of persuasion that the subject FMVSS No. 108 noncompliance is inconsequential to motor vehicle safety. Accordingly, Tesla’s petition is hereby denied, and Tesla is consequently obligated to provide notification of and free remedy for that noncompliance under 49 U.S.C. 30118 and 30120.”

The issue here appears to be the angle of the headlights and the brightness they emit during operation. The NHTSA report states that:

“Tesla’s headlamp supplier, Marelli Automotive Lighting, tested 25 right-hand and 25 left-hand lamps, and for this sample, found the maximum photometric intensity measured in the 10°U to 90°U and 90°L to 90°R zone was between 136.2 cd and 230.1 cd for the right-hand lamps and between 117.5 cd and 160.3 cd for the left-hand lamps. According to Tesla, these tests revealed that the photometric intensity of the right-hand and left-hand headlamp lower beam on the subject vehicles may measure as much as 230.1 cd in the 10°U to 90°U and 90°L to 90°R zone, exceeding the maximum photometric intensity by 105.1 cd. Additionally, Tesla states that a left-hand lamp tested by a Transport Canada recognized laboratory measured a maximum of 171.27 cd in the 10°U to 90°U and 90°L to 90°R zone. Despite these measurements exceeding the allowed photometric maximum of 125 cd, Tesla believes that the subject noncompliance is inconsequential to motor vehicle safety.”

Tesla also argued at some points that the headlights had not been deemed responsible for any complaints, accidents, or injuries related to the noncompliance.

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