Connect with us

News

SpaceX Super Heavy booster returns to launch pad after major repairs

Booster 7 has returned to the orbital launch site after suffering damage a few weeks prior. (NASASpaceflight - bocachicagal)

Published

on

SpaceX has returned its newest Super Heavy to Starbase’s orbital launch site (OLS) after rapidly repairing damage the booster suffered during its first round of testing.

Super Heavy Booster 7 (B7) left the High Bay it was assembled in for the first time on March 31st and rolled a few miles down the road to nearby Starship launch and test facilities on a set of self-propelled mobile transporters (SPMTs). On April 2nd, the roughly 67-meter-tall (~220 ft; 69m w/ Raptors) rocket was installed on top of Starbase’s lone orbital launch mount (OLM), setting the stage for crucial qualification testing.

The start of that process was exceptionally successful. On April 4th, after a smooth launch mount installation, SpaceX quickly filled Booster 7’s propellant tanks with a relatively benign cryogenic fluid (liquid nitrogen, liquid oxygen, or both) to simulate the thermal and mechanical characteristics of real flammable propellant. Despite the fact that the test marked the first time SpaceX had fully filled a Super Heavy prototype’s tanks, Booster 7 sailed through the ‘cryoproof’ without any obvious issue.

On April 8th, SpaceX moved Super Heavy B7 from the orbital launch mount to a structural test stand that had been installed and modified just a few hundred feet away in the weeks prior. This is where Booster 7’s near-perfect start to qualification testing took a bit of a turn. Booster 7 is only the third full-size Super Heavy prototype SpaceX has tested since July 2021. Like Booster 3 and Booster 4 before it, Booster 7 features some major design changes that ultimately make the prototype a pathfinder, necessitating extensive qualification testing.

To name just a few of the changes, Super Heavy B7 is the first booster fitted with a 33-engine puck and the first finished Starship prototype of any kind designed to use new Raptor V2 engines. With all 33 engines installed and operating a full thrust, Booster 7’s entire structure – and its aft thrust section especially – would be subjected to around 40% more thrust and stress than Booster 4, which indirectly completed structural testing with the help of a sacrificial test tank. Beyond differences in thrust and mechanical stress, Booster 7 is also the first Super Heavy to reach the test stand with secondary ‘header’ tanks meant to store landing propellant.

Advertisement

It’s unclear if those header tanks were fully filled and drained during Booster 7’s cryoproof, but they would not be quite as cooperative during a different kind of cryogenic testing on the structural test stand. The stand SpaceX modified specifically for Super Heavy B7 was outfitted with 13 hydraulic rams to simulate the full thrust of the booster’s central Raptor V2 engines – up to almost 3000 tons (~6.6M lbf) compared to Booster 4’s ~1700 tons (~3.7M lbf) with a smaller cluster of nine engines.

Implosion at the Structural Test Stand

After a few false starts and minor tests on the stand, Booster 7 finally managed some significant testing on April 14th. Judging by the rhythmic shattering of ice that built up on Super Heavy’s tanks, the test stand was able to simulate the thrust of Raptors to some degree and subject the booster to major mechanical stress that was felt from tip to tail. Within a few days, Booster 7 was removed from the test stand and returned to the high bay on April 18th. Around April 21st or 22nd, an image was leaked showing extensive damage inside Booster 7, confirming that the Super Heavy’s test campaign had been forced to end prematurely.

A leaked image looking up inside B7’s LOx header tank after testing. Above, B7’s aft section and LOx header before the booster was fully assembled.

Right away, the damage shown in the photo hinted at an operational failure, meaning that mistakes made by the rocket’s operators may have been more to blame than a possible design flaw. The photo shows a short portion of B7’s liquid methane (LCH4) transfer tube that runs through the booster’s new liquid oxygen (LOx) header tank, which itself sits inside Super Heavy’s main LOx tank at the aft end of the rocket – a tube inside a small tank inside a large tank, in other words. Super Heavy’s LCH4 transfer tube generally does what it says, allowing methane to safely fly down through the main LOx tank and fuel up to 33 Raptor engines. At full thrust, that tube would need to supply around 20 tons (~45,000 lb) of methane per second.

However, on top of merely transferring methane through the oxygen tank, Booster 7 introduced a design change that allows some or all of that tube to change functions and become a header tank mid-flight. That would require a system of valves that could seal off the main LCH4 tank once it was emptied, turning the transfer tube into a sort of giant steel straw filled with enough LCH4 to fuel Super Heavy’s boost-back and landing burns.

The damaged transfer tube in the leaked photo of Booster 7 doesn’t look that unlike what one might expect to see if they sucked through one end of a straw while blocking the other end, collapsing the center. Translated to the scale of Super Heavy, after an otherwise successful day of structural testing, SpaceX operators may have accidentally closed or opened the wrong valves while draining the booster’s transfer tube of liquid oxygen or nitrogen. As the heavy liquid drained from the tube, a lack of pressure equalization could have quickly drawn a vacuum and caused the tube to implode.

The

On April 29th, a SpaceX fan turned analyst published an analysis that convincingly pinpointed the moment Booster 7’s transfer tube collapsed. Simultaneously, because it showed that the transfer tube likely imploded during detanking, the analysis more or less confirmed the above speculation that the failure had been caused by a degree of operator error or poor test design. Of course, it’s possible that a hardware or software design flaw contributed to or caused the anomaly or that something like a pressure differential in the LOx header tank and LCH4 header tube could also explain the damage, but the accidental formation of a vacuum during detanking is arguably the simplest (obvious) explanation.

Advertisement

After the image of the internal damage leaked, the immediate consensus among fans and close followers was that Booster 7 was beyond repair. Instead, SpaceX appears to have proven those assumptions wrong and somehow managed to repair the upgraded Super Heavy to the point that it was worth testing again less than three weeks after returning to the high bay. On May 6th, B7 was rolled back to the launch site and installed, for the second time, on the orbital launch mount.

Prior to the failure, the general expectation was that SpaceX would begin installing Raptor V2 engines as soon as Booster 7 passed structural testing. It remains to be seen if SpaceX wants to repeat Booster 7’s cryoproof or structural testing to ensure that its quick repairs did the job before proceeding into static fire testing as previously planned. Nonetheless, hope lives on for the Super Heavy prototype and new test windows have been scheduled from 10am to 10pm on May 9th, 10th, and 11th.

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.

Advertisement
Comments

News

Tesla appears to have teased a long-awaited Model Y trim for a Friday launch

The company posted it with its Europe & Middle East account, and it appears to be a Model Y Performance, which has been spotted testing at the famed Nurburgring in Germany.

Published

on

Credit: Tesla

Tesla appears to have teased a long-awaited Model Y trim for a launch on Friday.

The company posted it with its Europe & Middle East account, and it appears to be a Model Y Performance, which has been spotted testing at the famed Nurburgring in Germany.

The Model Y Performance became a big-time hit after it packed the family-style interior with lightning-fast acceleration, speed, and handling.

As Tesla transitioned the Model Y into the updated “Juniper” design, the company took its time to create an even better vehicle with the new Performance configuration.

It has surely taken its time, but the vehicle appears to have undergone some exterior changes to enhance aerodynamics, handling, and overall performance.

We recently went into what was different about the test units spotted at Nurburgring in an article, but we’ll also list them here:

  • New 21″ wheels
  • All black headliner, a big change that was included in the Model Y L, the first time a Model Y has had that option
  • Updated brakes
  • Bucket seats that appear to be similar to the new Model Y L in China
  • New Carbon Fiber Spoiler
  • Performance Badging
  • Changes to both the front and rear bumper
  • Suspension with Adaptive Dampers

Tesla Model Y Performance zips around Nurburgring with new features

It does not seem like there’s much else it could be, but it is important to note that Tesla has been developing a handful of affordable models. There is a possibility that Tesla could launch one of these on Friday, but it seems unlikely.

The affordable models will likely be coming to the United States or China before they would in Europe.

They would be developed at Gigafactory Texas or Gigafactory Shanghai. The company stated in its Q2 Earnings Shareholder Deck that it had continued to expand its vehicle offerings and successfully manufactured the first builds of a more affordable model in June.

Volume production is planned for the second half of 2025.

Continue Reading

Elon Musk

SpaceX Starship Flight 10 was so successful, it’s breaking the anti-Musk narrative

That’s all the proof one could need about the undeniable success of Starship Flight 10.

Published

on

Credit: Elon Musk/X

Starship Flight 10 was a huge success for SpaceX. When both the Super Heavy booster and the Starship Upper Stage successfully landed on their designated splashdown zones, the space community was celebrating.

The largest and most powerful rocket in the world had successfully completed its tenth test flight. And this time around, there were no rapid unscheduled disassemblies during the mission.

As per SpaceX in a statement following Flight 10, “every major objective was met, providing critical data to inform designs of the next generation Starship and Super Heavy.” The private space enterprise also stated that Flight 10 provided valuable data by stressing the limits of Starship’s capabilities.

With all of Flight 10’s mission objectives met, one would think that it would be pretty easy to cover the story of Starship’s successful tenth test flight. But that’s where one would be wrong, because Elon Musk companies, whether it be Tesla or SpaceX or xAI, tend to attract negative slant from mainstream media outlets.

This was in full force with Starship Flight 10’s coverage. Take the BBC’s Facebook post about the fight test, which read “Elon Musk’s giant rocket, earmarked for use in a 2027 mission to the Moon, has had multiple catastrophic failures in previous launches.” CNN was more direct with its slant, writing “SpaceX’s troubled Starship prototype pulls off successful flight after months of explosive mishaps” on its headline. 

Advertisement

While some media outlets evidently adopted a negative slant towards Starship’s Flight 10 results, several other media sources actually published surprisingly positive articles about the successful test flight. The most notable of which is arguably the New York Times, which featured a headline that read “SpaceX’s Giant Mars Rocket Completes Nearly Flawless Test Flight.” Fox News also ran with a notably positive headline that read “SpaceX succeeds at third Starship test flight attempt after multiple scrubs.”

Having covered Elon Musk-related companies for the better part of a decade now, I have learned that mainstream coverage of any of his companies tends to be sprinkled with varying degrees of negative slant. The reasons behind this may never be fully explained, but it is just the way things are. This is why, when milestones such as Starship’s Flight 10 actually happen and mainstream media coverage becomes somewhat objective, I can’t help but be amazed. 

After all, it takes one heck of a company led by one heck of a leader to force objectivity on an entity that has proven subjective over the years. And that, if any, is all the proof one could need about the undeniable success of Starship Flight 10.

Continue Reading

Elon Musk

Tesla’s Elon Musk takes another shot at Waymo’s capabilities stemming from LiDAR

“LiDAR also does not work well in snow, rain or dust due to reflection scatter. That’s why Waymos stop working in any heavy precipitation.”

Published

on

tesla elon musk

Tesla CEO Elon Musk has frequently expressed his opinions on LiDAR in the past, but in recent days, the EV maker’s frontman has continued to discuss the weaknesses in the technology and why his company has relied on cameras.

He also mentioned the suite’s limits on Waymo’s capabilities.

Tesla completely abandoned using radar alongside its camera suite a few years ago, something it referred to as “Tesla Vision” at the time. For its vehicles, it has only used cameras since this transition, and Musk has never once shied away from this strategy.

Earlier this week, he discussed the reliance of LiDAR and radar by other companies:

“Lidar and radar reduce safety due to sensor contention. If lidars/radars disagree with cameras, which one wins?

This sensor ambiguity causes increased, not decreased, risk. That’s why Waymos can’t drive on highways.

We turned off radars in Teslas to increase safety. Cameras ftw.”

Elon Musk argues lidar and radar make self driving cars more dangerous

He continued with this narrative again and mentioned Waymo specifically on a second occasion.

Musk’s focus this time was on Waymo vehicles and their capabilities in adverse weather, specifically snow, rain, or even dust storms, and how LiDAR struggles to navigate in these conditions.

He said:

“LiDAR also does not work well in snow, rain or dust due to reflection scatter. That’s why Waymos stop working in any heavy precipitation. As I have said many times, there is a role for LiDAR in some circumstances and I personally oversaw the development of LiDAR for the SpaceX Dragon docking with Space Station. I am well aware of its strengths and weaknesses.”

Tesla’s approach is significantly different than most companies. Waymo, Motional, Aurora, and Zoox all use LiDAR for their self-driving programs, while Tesla continues to rely on its camera-only approach.

Musk even said that Model S and Model X utilized a Tesla-developed high-resolution radar, but it could not “compare to passive optical (cameras), so we turned it off.”

Continue Reading

Trending