NASA astronauts Butch Wilmore and Suni Williams have found themselves in an extended stay on the International Space Station (ISS). This is due to ongoing issues with Boeing’s Starliner spacecraft which launched in early June.

Originally scheduled to return home, the astronauts’ mission has been delayed indefinitely due to concerns over thruster problems and several helium leaks in the Starliner’s engine system.

As a result, NASA has indicated that Wilmore and Williams may remain on the ISS until the next scheduled crew switchover in August, potentially returning on a different spacecraft.

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Boeing’s Starliner Issues

Boeing and NASA have attempted to present the extension of the astronauts’ stay as an opportunity to test systems required for longer Starliner missions. However, the project has already faced numerous delays, having originally been slated for its first crewed launch in 2017.

These persistent issues raise significant questions about the overall viability of the Starliner program.

Prior to its launch, Starliner was identified as having a minor helium leak. Helium, an inert gas similar to neon or xenon, is highly unreactive, making it suitable for use with rocket fuel and in high-temperature environments.

Despite the expense of producing helium, it is critical for pushing fuel into the engines at the correct rate. A helium leak can prevent sufficient fuel from reaching the thrusters.

The first attempt to dock at the ISS was aborted after engineers detected issues with the reaction control thrusters, which are vital for precise docking maneuvers. Nevertheless, a subsequent “hotfire” test reactivated at least four thrusters, enabling Starliner to achieve its first autonomous docking with the ISS.

Despite this milestone, concerns persist about the thrusters potentially failing during the return journey to Earth. The re-entry phase requires a precise "angle of attack" to manage friction and heat buildup on the vessel, making reliable thrusters crucial.

Trouble Shooting

Boeing and NASA engineers have dedicated the past month to ground tests on a Starliner Reaction Control System (RCS) thruster, investigating the problems encountered during the flight in early June.

Boeing recently announced that the teams were able to replicate the thrust degradation experienced by Starliner and are now analyzing the collected data. However, the exact return date for astronauts Wilmore and Williams remains uncertain, with NASA and Boeing stating only that the trip will occur “in the coming weeks.”

At the White Sands Test Facility in New Mexico, engineers simulated conditions from Starliner’s recent flight, subjecting the control system thruster to over 1,000 pulses to mimic Crew Flight Test (CFT) conditions.

These tests included scenarios for undocking and deorbit burns, which Starliner will face on its return journey. After collecting extensive data, the teams conducted additional, more aggressive tests to replicate the higher thermal conditions experienced in-flight, as explained by Dan Niedermaier, Boeing’s engineer for thruster testing.

The current phase involves “engine tear downs and inspections,” according to NASA’s Commercial Crew Program manager, Steve Stich.

Following these analyses, an Agency Flight Test Readiness Review will determine whether Starliner is ready to safely bring the astronauts back to Earth.

NASA and Boeing have promised to provide more information in an upcoming conference call.