FAA Approves SpaceX for 10th Starship Test Flight on August 24

The Federal Aviation Administration (FAA) has granted SpaceX the green light to proceed with its 10th test flight of the Starship rocket, tentatively scheduled for August 24. This approval marks a significant milestone following a thorough investigation into the anomalies encountered during the previous Starship mission, known as Flight 9.

The FAA’s determination, announced on a recent Friday morning, signifies the closure of an inquiry into the mishap that occurred during Flight 9. This particular test involved the Super Heavy first stage, designated as Booster 14, in its second flight, paired with Ship 35. The investigation aimed to diagnose the issues that led to the loss of the Starship vehicle during reentry.

According to the FAA’s final report, the primary cause of the failure was identified as a malfunction within a fuel component. Citing the FAA, “The final mishap report cites the probable root cause for the loss of the Starship vehicle as a failure of a fuel component. SpaceX identified corrective actions to prevent a reoccurrence of the event.”

The performance during Flight 9 was somewhat of a mixed bag. While Ship 35 did successfully ascend and reach engine cutoff, it subsequently lost attitude control during the coast phase. This instability led to an uncontrolled reentry, ultimately resulting in the vehicle’s destruction upon atmospheric entry.

In its aftermath, SpaceX was mandated by the FAA to conduct an extensive review and submit a detailed report specifying the causes of the failure and proposed corrective measures. Post-investigation, SpaceX determined that a critical failure in a component known as the diffuser, located at the top of the forward dome in the methane tank, was responsible for the anomaly.

The diffuser’s failure resulted in a leak that allowed liquid methane to seep into the nosecone area. This unexpected influx of liquid methane instigated a rapid cooling of critical systems, prompting automatic commands that vented all remaining propellant into space. The successful reproduction of this failure mode in their McGregor, Texas testing facilities enabled SpaceX engineers to implement a redesign of the diffuser, aimed at mitigating structural strain. These updated diffusers have already undergone rigorous qualification testing.

In addition to addressing the issues from Flight 9, SpaceX faced further challenges when Ship 36, originally slated for Flight 10, exploded during pre-launch ground tests in June. This incident, while not subject to an FAA investigation since it occurred before the flight, led to an internal review by SpaceX. Engineers identified that undetectable or under-screened damage to a composite overwrapped pressure vessel (COPV) in the payload bay of Starship caused structural failure and subsequent ignition due to propellant mixing.

In response to the findings from both investigations, SpaceX is enhancing its inspection procedures and proof testing of COPVs. They’re also planning to reduce the operational pressure of these components to further mitigate risks in future flights.

With both investigations now concluded, attention shifts toward the upcoming Flight 10. The launch window will open at 6:30 p.m. Central Time on August 24, lasting for one hour, featuring a combination of Booster 16 and Ship 37.

SpaceX has announced plans to reattempt a variety of experiments from its previous Block 2 ship flights. These will include ascent and coast maneuvers for the upper stage, as well as entry and landing tests for the booster, similar to those attempted during Flight 9. Each of these flights is critical, as they build upon lessons learned from earlier missions, driving progress toward operational readiness.

As SpaceX moves forward with its ambitious goals, the next two flights with the Block 2 variation will serve as a transitional period focused on gathering vital data before advancing to Version 3 of the vehicle, which is expected to launch from Pad 2. This new variant will incorporate insights gleaned from earlier flights and will aim for regular operational use from Kennedy Space Center’s historic Launch Complex 39A, anticipated to be active next year.