The Boeing drama continues

These are not good times for Boeing. After problems with its commercial aircraft manufacturing, and changing two CEOs in short order, its approach to the space industry is not going well either.

Fortunately, the Starliner, the reusable spacecraft designed to transport astronauts to the International Space Station (ISS), suffered a serious leak, after it had already left the astronauts on the station.

Developed in cooperation with NASA from its inception, the project was intended not only to provide an alternative to the Russian Soyuz spacecraft, but also to foster the growth of the commercial space industry in the United States. However, the road to success was full of obstacles.

Technical problems and leaks

Since its early days, the Starliner has faced many technical problems. Most notable was a failure during a drone flight test in December 2019, where a mission timer error prevented the ship from reaching the International Space Station. This incident underscored the need for extensive reviews and improvements of the ship’s systems.

The following year, 2020, Starliner had to pass a series of critical tests to prove its ability to safely carry out manned missions. Each of these steps was necessary to restore confidence in the spacecraft and Boeing’s ability to meet NASA’s safety standards.

Despite the setbacks, the Starliner finally took off successfully on June 5, 2024, aboard an Atlas 5 rocket, carrying astronauts Butch Wilmore and Sonny Williams to the International Space Station. This achievement was critical for Boeing to obtain NASA certification for future crew rotation missions. However, the flight was not without tensions, with multiple helium leaks and problems with the reaction control thrusters detected.

Specifically, the Boeing ship could suffer up to five helium leaks, and it already had all of them upon its return.

The five helium leaks: an ongoing problem

The first leak was discovered shortly after the initial crewed mission was launched, due to a faulty valve in the Atlas V rocket. This problem caused the first major flight delay. The discovery of this leak highlighted the fragility of Starliner’s systems and the need for constant monitoring.

During the flight to the International Space Station, two additional leaks were discovered in the propulsion system’s helium assemblies. These incidents occurred at critical moments in the flight, when the astronauts were about to begin their rest period. The rapid response allowed engineers to temporarily contain the situation by shutting down the helium accumulators.

After docking at the ISS, two more leaks were identified, bringing the total to five. Although Boeing confirmed that the ship could withstand up to five leaks without compromising its safety, the situation raised concern. NASA and Boeing stated that these leaks, although small, could have major impacts if not managed properly.

NASA and Boeing analysis

NASA and Boeing engineers are evaluating the potential effects of the leaks on the mission. According to a NASA statement, the Starliner vehicle has enough helium in its tanks to support 70 hours of free flight activity, which is more than enough for its return to Earth, scheduled for June 18. However, leaks have forced helium manifolds to remain closed, which must be opened for separation and deorbit maneuvers.

Engineers work around the clock to ensure all systems function optimally during separation and reentry into Earth’s atmosphere.

These recurring problems raise serious questions about the Starliner’s reliability on future missions. Boeing and NASA will need to work closely to resolve these failures and ensure that future missions do not face the same challenges. Boeing’s ability to address these issues will largely determine the success of the program in the future.

The future of the Starliner affects not only Boeing, but also NASA’s broader strategy to encourage commercial participation in space. If Boeing cannot resolve these issues, NASA may have to rely more heavily on SpaceX and other commercial suppliers to meet crew rotation goals.