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SpaceX Rocket Engine Explodes During Test (space.com)

According to The Washington Post, a SpaceX rocket engine exploded Sunday (Nov. 5) at the company's test facility in McGregor, Texas. The explosion reportedly occurred during a "qualification test" of a Merlin engine, the type that powers SpaceX's workhorse Falcon 9 rocket. Space.com reports: SpaceX has suspended engine testing while it investigates what caused the incident, which didn't injure anyone, the Post added. In a statement provided to the Post, SpaceX representatives said they didn't expect the explosion to affect the company's launch schedule. That schedule has been pretty packed this year. SpaceX has already launched 16 missions, all of them successful, in 2017 -- twice as many as its previous high in a calendar year. And all but three of these missions also involved landings of the Falcon 9 first stage, for eventual refurbishment and reuse.

34 of 115 comments (clear)

  1. Incident occured during a LOX test by Strider- · · Score: 4, Informative

    The incident in question did not occur during an engine firing. Rather they were performing a "LOX drop" test which basically involves pumping LOX through the engine and checking for leaks. Something went wrong in this process, causing the damage. Until the investigation is completed, there's no way to know whether it was an issue with the engine, the test rig, or the setup. It might be that a tech just dind't tighten something adequately, or a filler hose leaked or whatever. SpaceX won't know until they complete their investigation, and we may never know.

    To quote Adam Savage of Mythbusters fame "LOX makes anything flammable. LOX makes something flammable into a high explosive." So even if they just had a sufficiently large leak, and the LOX leaked onto/into asphalt or similar, all it takes is a spark to cause that asphalt to detonate like a bunch of dynamite.

    --
    ...si hoc legere nimium eruditionis habes...
    1. Re:Incident occured during a LOX test by Bruce+Perens · · Score: 4, Informative

      Also, this was a block 5 engine. There are newly designed un-flown parts in that engine, ironically because NASA asked for higher reliability for human missions. For example no more turbopump impeller cracks, which SpaceX had characterized and was tolerating on cargo missions using the older impellers. For something to go wrong during a test of new designs is to be expected.

    2. Re:Incident occured during a LOX test by Bruce+Perens · · Score: 5, Interesting

      We should also remember that SpaceX had an engine fail destructively on the CRS-1 mission. The design of the rocket contains such a failure in one engine without damaging the others. The rocket had an engine-out capability that can cope with one or more failures. It compensated and completed the mission, achieving all expected parameters on the remaining 8 first-stage engines.

    3. Re:Incident occured during a LOX test by Bruce+Perens · · Score: 4, Informative

      There is probably a nitrogen test before the LOX is let in to the engine. But remember that LOX is its oxidizer, and it has to be run with it eventually because the engine can't work without it. And you don't want to test more than one variable at once if you don't have to, so the LOX gets let in without the fuel first. So, this test is essential.

      LOX is very nasty stuff and it is prudent to test with it. Suppose you had a vendor issue and you got an organic rubber O-ring in the system rather than one that can deal with LOX? You would find out, destructively, when the LOX came in.

    4. Re:Incident occured during a LOX test by ravenshrike · · Score: 2

      You need something that has the expansion characteristics of LOX and is a liquid at the same temperatures. Good luck finding it.

    5. Re: Incident occured during a LOX test by oobayly · · Score: 2

      That just means that F9 has been over engineered for every mission where an engine didn't fail! /s

  2. Well.. by fluffernutter · · Score: 3, Insightful

    I'm no Musk fan, but what's why you test?

    --
    Laws are rules for the court, but merely a bottom bar to hit for life. Think beyond laws in your actions always.
    1. Re:Well.. by Anonymous Coward · · Score: 5, Funny

      I'm no Musk fan, but what's why you test?

      No, who's why you test.

      What's on second.

    2. Re:Well.. by TheReaperD · · Score: 4, Insightful

      Yea, I'm not sure why this is news. They did a test and it failed with no injuries because they did the test safely. Other than some acceptable losses and likely the loss of the engine, there was no harm. This is why you test things like this.

      --
      "Be particularly skeptical when presented with evidence confirming what you already believe." -
    3. Re:Well.. by turkeydance · · Score: 2

      i don't know

    4. Re:Well.. by Bruce+Perens · · Score: 2

      Because the next mission will probably feature the 20th first-stage recovery. Which is totally in-f**king-credible if you ask me. And it's really hard to find anything to take them down with at the moment, even though there are folks who seem determined to do so.

    5. Re:Well.. by just+another+AC · · Score: 2

      no he's on third

    6. Re:Well.. by jwhyche · · Score: 4, Interesting

      I for one, am glad its news. I would like to get back to "news for nerds" with stories like this.

      --
      I read at +2. If your post doesn't reach that level I will not see or respond to it.
  3. Re:Well by ShanghaiBill · · Score: 4, Insightful

    That’s what happens when you cut corners and half ass things to make things cheaper.

    Launch costs need to be cheaper. The trick is to figure out which corners can be cut, and which can not. Engineers learn by trying and failing, and I am sure SpaceX learned some valuable lessons today.

    "Ever tried. Ever failed. No matter. Try Again. Fail again. Fail better." - Samuel Beckett

  4. Merlin engine? by Deadstick · · Score: 2

    That's a 1650-cubic inch V-12.

    1. Re:Merlin engine? by Deadstick · · Score: 2

      Thanks. Fun fact: The Merlin is named for a bird, not a sorceror. Rolls-Royce named a long series of aero engines after birds, beginning with the Eagle in 1915. They switched to rivers for their gas turbine engines, like the long-running Dart series -- but that's also the name of a bird!

      For that matter, Arthur's sorceror was named for the bird too: Druids named their children after living things.

  5. Re:Well by used2win32 · · Score: 5, Informative

    At least this happened with the new Merlin Series 5 redesign, scheduled for flight next year.
    The current Series 4 engines have been pretty reliable so far...

    --
    Procrastination; I'll think of a sig tomorrow.
  6. test by 4wdloop · · Score: 2

    the nature of test is to find faults
    if everything was perfect by design the test people would be flipping burgers or work as perfect-design engineers

    --
    4wdloop
  7. Some other sources by XXongo · · Score: 5, Informative

    At least this happened with the new Merlin Series 5 redesign, scheduled for flight next year.

    Exactly. That's important-- this is the next generation engine, not the one currently flying.

    Some alternate sources, some with more information:
    https://www.space.com/38712-spacex-rocket-engine-test-explosion.html
    https://www.geekwire.com/2017/next-generation-spacex-rocket-engine-goes-flames-texas-test/
    https://arstechnica.com/science/2017/11/an-experimental-spacex-rocket-engine-has-exploded-in-texas/
    https://www.theverge.com/2017/...

  8. Re: Well by Anonymous Coward · · Score: 3, Insightful

    No, then they wouldn't test at all.

    My reaction to this is more like:

    Yeah so, this is why they test.

  9. Re: Well by Type44Q · · Score: 4, Insightful

    No, not quite; more like "this is why we have tests."

  10. Re: Merlins engines powered the Spitfires by Type44Q · · Score: 3, Insightful

    Flattery's an insult? You must've read 1984.

  11. They named it after the falco columbarius? by mykepredko · · Score: 2

    The Rolls Royce "merlin", like other Rolls Royce aero engines of the time, was named after a bird of prey. The bird they named the engine after is a type of falcon which is called a "pigeon hawk" in North America and "merlin" in Europe.

    So, did SpaceX name their engine after the bird (and Rolls Royce's engine) or the mythical wizard?

    Doing a quick search and there's no clear answer.

    1. Re:They named it after the falco columbarius? by Required+Snark · · Score: 2
      Musk knows his science fiction. The rockets are named Falcon because of the Millennium Falcon in Star Wars. If you think of that as being the Falcon 1000 then it makes sense for the current rocket only have a one digit number. The numbering represents the distance between the current state of the art and the dream of interstellar space flight.

      SpaceX ocean landing barges also take names from science fiction. They are named after Minds, superhuman artificial intelligences in the in Bank's Culture Universe.

      On 23 January 2015, SpaceX's CEO and Chief Designer Elon Musk named two of the company's autonomous spaceport drone ships Just Read The Instructions and Of Course I Still Love You, after ships from Banks's novel The Player of Games.

      Banks died on 9 June 2013.

      --
      Why is Snark Required?
  12. Zero parts failures in test = too expensive by raymorris · · Score: 2

    You're partly right. If you're being smart economically, or advancing technology, you'll test some things that don't work. If everything you test works, you're a) doing the same boring shit that's been done and b) over-engineering, making things much more expensive than they should be.

    Testing is how you find out what works and what doesn't, and how much you need to spend to make things work reliably.

    1. Re:Zero parts failures in test = too expensive by just+another+AC · · Score: 2

      If everything you test works, you're a) doing the same boring shit that's been done and b) over-engineering, making things much more expensive than they should be.

      or
      c) you aren't testing correctly (thoroughly enough)

      Why do people always overlook that one?!?!

  13. Ignition! by pz · · Score: 4, Interesting

    There is a marvelous history of the development of rocket fuel called, "Ignition!", written by John D. Clark, one of the field's insiders who has an ascerbic wit. The foreword was written by Isaac Asimov, which contains the following fantastic quote:

    Now it is clear that anyone working with rocket fuels is outstandingly mad. I don't mean garden-variety crazy or a mere raving lunatic. I mean a record-shattering exponent of far-out insanity.

    There are, after all, some chemicals that explode shatteringly, some that flame ravenously, some that corrode hellishly, some that poison sneakily, and some that stink stenchily. As far as I know, though, only liquid rocket fuels have all these delightful properties combined into one delectable whole.

    Explosions are par for the course. Rocket science is hard.

    --

    Put my fist through my alarm clock with its ding-dong death inside my ear. - The Blackjacks.
    1. Re:Ignition! by Anonymous Coward · · Score: 2, Informative

      A link to a downloadable copy is probably a good idea at this point. Scroll down a bit to the download options.

      https://archive.org/details/ignition_201612

  14. Re: Well by ShanghaiBill · · Score: 5, Interesting

    Ok, then, can we get ULA on a level playing field with cutting corners?

    You are being silly. This was R&D, not a production launch.

    Right now ULA is required to do the full engineering work up for every launch, v.s. spaceX not

    1. This was not a "launch"
    2. It should be up to the market.

    ULA provides expensive reliability. SpaceX provides discount access to orbit. If you are launching a 5 billion dollar GSO comsat, you will go with ULA. If you want to dump a van load of cubesats designed by high school science clubs into LEO, you go with SpaceX.

    SpaceX will get more reliable much faster than ULA will get cheaper. In ten years, ULA will be out of business.

  15. Re:Merlins engines powered the Spitfires by Anonymous Coward · · Score: 5, Insightful

    amazing how you have invented up new ways of being offended.

  16. Re: Well by Anonymous Coward · · Score: 4, Informative

    SpaceX provides discount access to orbit. If you are launching a 5 billion dollar GSO comsat, you will go with ULA. If you want to dump a van load of cubesats designed by high school science clubs into LEO, you go with SpaceX.

    DoD is launching with SpaceX now, so they have definitely jumped up in the rankings compared to ULA, and the various state-owned launchers. Cubesats and science projects are becoming the domain of start-ups that NASA is funding

    FWIW the accident involved a new block-5 merlin engine that was undergoing lox load testing for leaks and 'something' caught fire, damaging the test facility, and presumably the engine, severely. It has not been determined if the engine, which was not firing, was at fault.

  17. Re: Well by 4im · · Score: 2

    If you are launching a 5 billion dollar GSO comsat, you will go with ULA. If you want to dump a van load of cubesats designed by high school science clubs into LEO, you go with SpaceX.

    I suppose those expensive GSO sats (TV & comm) that SES, largest commercial sat operator, is having launched by SpaceX, even on refurbished SpaceX launchers (SES being first commercial customer), must be cubesats... NOT!

    SES being a for-profit corporation, they run the numbers... and they don't seem to do much business with ULA (as compared to SpaceX, Arianespace, Proton...).

  18. Re:Well by gweihir · · Score: 2

    Oh, yes. A failure during a test is nothing unexpected. It is where failures are supposed to happen. Anybody that does not understand that does not know the first thing about engineering. And a "qualification test" in particular serves to find the occasional manufacturing fault still present before it does real damage.

    --
    Most ACs are not even worth the keystrokes to insult them. Be generically insulted by this and ignored otherwise.
  19. Re:Well by networkBoy · · Score: 2

    I was thinking the same thing.
    Mishaps on the test stand is what the thing is built for.
    Even a massive explosion with all equipment lost is a success because it thus did not happen on a launch pad where in addition to the lost equipment you very well may/will lose:
    * The Payload.
    * The Launchpad Facility.
    * The actual Launchpad.
    * Lives.
    * Delay to future launches of unknown duration because of aforementioned damage.

    Sure it's a suboptimal success, but it is still not a failure.

    --
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