Boeing plans to redesign problematic valve that kept Starliner from flying NASA astronauts

Boeing’s Starliner capsule for the Orbital Flight Test 2 (OFT-2) mission is lifted atop United Launch Alliance’s Atlas V rocket on May 4, 2022.

Frank Michaux/NASA

Boeing is considering whether to redesign the propulsion valves on its Starliner crew capsule, a crucial system that has prevented the company from flying astronauts for NASA – and competing with Elon Musk’s SpaceX.

Starliner is the spacecraft that Boeing developed under NASA’s Commercial Crew program, after winning nearly $5 billion in contracts to build the capsule. But the development of Starliner ran into several obstacles. A software malfunction halted the first uncrewed orbital flight in 2019, and a propulsion valve problem was identified before the launch of the second attempt last August.

“A redesign of the valves is definitely on the table,” Mark Nappi, Boeing vice president and Commercial Crew program manager, said at a press conference Wednesday. “Once we get all the information we need, we will make that decision.”

Boeing is trying again to launch the Orbital Flight Test 2 (OFT-2) mission, which is scheduled to lift off May 19 from Florida. For this attempt, the company applied a sealant to the valves. But the fix is ​​likely a temporary solution to the problem which in August saw 13 of the 24 oxidizer valves that control Starliner’s movement in space jam after launch site humidity caused corrosion .

Depending on the outcome of OFT-2, Boeing would then prepare for a crewed flight test that would see the first astronauts fly Starliner. However, a redesign of the valve could further delay this crewed launch, given the need for Boeing to test the fix and for NASA to certify the solution.

To date, Boeing has spent $595 million due to work delays under a fixed-price contract with NASA to develop Starliner. Last year, the space agency made the rare decision to reassign astronauts from Starliner to SpaceX’s Crew Dragon, which has just launched the company’s seventh manned spaceflight.

Reuters first reported, citing sources, that Boeing will be redesigning Aerojet Rocketdyne-made propulsion valves, although neither the aircraft maker nor NASA has previously revealed the plans. Nappi confirmed that Boeing “has been exploring options for at least a month, if not longer.”

For now, Nappi said Boeing wants to “do a little more testing” to better understand how “those nitrates form inside” the valves, with those results guiding a team that has been set up.

“We are very confident for OFT-2 that we have a system that will work well,” Nappi said.

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