Boeing and NASA are having trouble returning astronauts

Helium leaks and propulsion problems are prompting NASA and Boeing to delay the return of astronauts to Earth aboard the company’s Starliner spacecraft. Boeing has successfully transported NASA astronauts to the International Space Station after weeks of delay. Their return to Earth in the same spacecraft proves to be another, very different challenge for the mission leaders.

The Wall Street Journal reported that problems with leaks and thrusters emerged after the launch of Boeing’s Starliner spacecraft this month with astronauts Barry Wilmore and Sunita Williams on board. The astronauts are expected to return on June 26, the airline and the National Aeronautics and Space Administration (NASA) said on Tuesday.

With the latest delay, astronauts will spend about 20 days in space, more than double the eight days originally planned. The Starliner flight has been plagued almost since day one.

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The Starliner had two major problems: a series of helium leaks in the propulsion system and problems with the various propulsion devices used to maneuver the vehicle. NASA and Boeing teams are considering both issues before allowing the Starliner spacecraft to attempt to leave the station with Wilmore and Williams, reenter Earth’s atmosphere and land by parachute.

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“We need more time to process what we saw and make sure we have all the plans in place to bring the crew home,” NASA program manager Steve Stich said on Tuesday. The Starliner vehicle is capable of transporting crew members to Earth in emergency situations, Stitch said. But they want to analyze the Starliner and the technical challenges it faces while on the station.

NASA officials said the space station has at least four months’ worth of food and other consumables for the astronauts on board. The Starliner could remain tied to the station for 45 days, although it is ultimately intended to remain there for six-month missions, they said.

Long stays on the ISS have occurred in the past. In September, NASA astronaut Frank Rubio returned to Earth after spending more than a year at the facility, a record flight for an American. His return was delayed after a small meteorite caused a hole in the Russian-made return vehicle and Russia sent another ship.

The press conference came on the same day that Boeing CEO David Calhoun testified before Congress and apologized for continuing quality problems at the plane manufacturer and the families who lost loved ones in two 737 MAX crashes. More problems with Starliner will further damage the company’s credibility.

The Starliner will only be separated if it can be done completely safely

The Starliner flight delay represents another setback for Boeing, which had been hoping for its first astronaut flight in years. Boeing has a contract with NASA to conduct six more crewed flights to the space station if it receives the agency’s certification of the vehicle. SpaceX has been transporting cargo to the space station for years and completed its first astronaut mission on behalf of NASA in 2020.

Mike Leinbach, former space shuttle launch director at NASA’s Kennedy Space Center, said mission officials would not allow the Starliner vehicle to return to Earth with the astronauts if the vehicle might pose risks to them.

“This vehicle has more problems than I expected,” said Leinbach, who was not involved in the Starliner mission. “We were hoping for a clean trip, but we didn’t get it and we’re dealing with that. They’ll find a solution.” Mark Nappi, Boeing’s vice president overseeing the Starliner program, said during the press conference that the Starliner’s crewed flight has achieved 77 out of 87 test goals so far.

NASA and Boeing are investigating five helium leaks found in the vehicle’s service module, the propulsion system that includes the thrusters. One was found before the journey began. The Starliner needs about seven hours of onboard sunlight to complete the flight, with about 70 hours remaining.

Five of the Starliner’s engines experienced a temporary failure when the vehicle reached the ISS’s terminal, but four of them returned to service. Stich stated that one of the engines would be disabled for the remainder of the mission.