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While ULA studies Vulcan booster anomaly, it’s also investigating fairing issues

A little more than a year ago, a snippet of video that wasn't supposed to go public made its way onto United Launch Alliance's live broadcast of an Atlas V rocket launch carrying three classified surveillance satellites for the US Space Force and the National Reconnaissance Office.

On these types of secretive national security missions, the government typically requests that the launch provider stop providing updates on the ascent into space when the rocket jettisons its two-piece payload fairing a few minutes after launch. And there should be no live video from the rocket released to the public showing the fairing separation sequence, which exposes the payloads to the space environment for the first time.

But the public saw video of the clamshell-like payload fairing falling away from the Atlas V rocket as it fired downrange from Cape Canaveral, Florida, on September 10, 2023. It wasn't pretty. Numerous chunks of material, possibly insulation from the inner wall of the payload shroud's two shells, fell off the fairing. The video embedded below shows the moment of payload fairing jettison.

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Β© NASA/Christian Mangano

Rocket Report: Sneak peek at the business end of New Glenn; France to fly FROG

Welcome to Edition 7.17 of the Rocket Report! Next week marks 10 years since one of the more spectacular launch failures of this century. On October 28, 2014, an Antares rocket, then operated by Orbital Sciences, suffered an engine failure six seconds after liftoff from Virginia and crashed back onto the pad in a fiery twilight explosion. I was there and won't forget seeing the rocket falter just above the pad, being shaken by the deafening blast, and then running for cover. The Antares rocket is often an afterthought in the space industry, but it has an interesting backstory touching on international geopolitics, space history, and novel engineering. Now, Northrop Grumman and Firefly Aerospace are developing a new version of Antares.

As always, we welcome reader submissions. If you don't want to miss an issue, please subscribe using the box below (the form will not appear on AMP-enabled versions of the site). Each report will include information on small-, medium-, and heavy-lift rockets as well as a quick look ahead at the next three launches on the calendar.

Astra gets a lifeline from DOD. Astra, the launch startup that was taken private again earlier this year for a sliver of its former value, has landed a new contract with the Defense Innovation Unit (DIU) to support the development of a next-gen launch system for time-sensitive space missions, TechCrunch reports.Β The contract, which the DIU awarded under its Novel Responsive Space Delivery (NRSD) program, has a maximum value of $44 million. The money will go toward the continued development of Astra’s Launch System 2, designed to perform rapid, ultra-low-cost launches.

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Β© Blue Origin

ULA is examining debris recovered from Vulcan rocket’s shattered booster nozzle

When the exhaust nozzle on one of the Vulcan rocket's strap-on boosters failed shortly after liftoff earlier this month, it scattered debris across the beachfront landscape just east of the launch pad on Florida's Space Coast.

United Launch Alliance, the company that builds and launches the Vulcan rocket, is investigating the cause of the booster anomaly before resuming Vulcan flights. Despite the nozzle failure, the rocket continued its climb and ended up reaching its planned trajectory heading into deep space.

The nozzle fell off one of Vulcan's two solid rocket boosters around 37 seconds after taking off from Cape Canaveral Space Force Station on October 4. There were some indications of a problem with the booster a few seconds earlier, as tracking cameras observed hot exhaust escaping just above the bell-shaped nozzle, which is bolted to the bottom of the booster casing.

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Β© United Launch Alliance

ULA’s second Vulcan rocket lost part of its booster and kept going

United Launch Alliance's Vulcan rocket, under contract for dozens of flights for the US military and Amazon's Kuiper broadband network, lifted off from Florida on its second test flight Friday, suffered an anomaly with one of its strap-on boosters, and still achieved a successful mission, the company said in a statement.

This test flight, known as Cert-2, is the second certification mission for the new Vulcan rocket, a milestone that paves the way for the Space Force to clear ULA's new rocket to begin launching national security satellites in the coming months.

While ULA said the Vulcan rocket continued to hit its marks during the climb into orbit Friday, engineers are investigating what happened with one of its solid rocket boosters shortly after liftoff.

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Β© Paul Hennessy/Anadolu via Getty Images

ULA hasn’t given up on developing a long-lived cryogenic space tug

The second flight of United Launch Alliance's Vulcan rocket, planned for Friday morning, has a primary goal of validating the launcher's reliability for delivering critical US military satellites to orbit.

Tory Bruno, ULA's chief executive, told reporters Wednesday that he is "supremely confident" the Vulcan rocket will succeed in accomplishing that objective. The Vulcan's second test flight, known as Cert-2, follows a near-flawless debut launch of ULA's new rocket on January 8.

β€œAs I come up on Cert-2, I’m pretty darn confident I’m going to have a good day on Friday, knock on wood," Bruno said. "These are very powerful, complicated machines."

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Β© United Launch Alliance

ULA hasn’t given up on developing a long-lived cryogenic space tug

The second flight of United Launch Alliance's Vulcan rocket, planned for Friday morning, has a primary goal of validating the launcher's reliability for delivering critical US military satellites to orbit.

Tory Bruno, ULA's chief executive, told reporters Wednesday that he is "supremely confident" the Vulcan rocket will succeed in accomplishing that objective. The Vulcan's second test flight, known as Cert-2, follows a near-flawless debut launch of ULA's new rocket on January 8.

β€œAs I come up on Cert-2, I’m pretty darn confident I’m going to have a good day on Friday, knock on wood," Bruno said. "These are very powerful, complicated machines."

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Β© [CDATA[United Launch Alliance]]

NASA is ready to start buying Vulcan rockets from United Launch Alliance

The first stage of ULA's second Vulcan rocket was raised onto its launch platform August 11 at Cape Canaveral Space Force Station, Florida.

Enlarge / The first stage of ULA's second Vulcan rocket was raised onto its launch platform August 11 at Cape Canaveral Space Force Station, Florida. (credit: United Launch Alliance)

United Launch Alliance is free to compete for NASA contracts with its new Vulcan rocket after a successful test flight earlier this year, ending a period where SpaceX was the only company competing for rights to launch the agency's large science missions.

For several years, ULA was unable to bid for NASA launch contracts after the company sold all of its remaining Atlas V rockets to other customers, primarily for Amazon's Project Kuiper Internet network. ULA could not submit its new Vulcan rocket, which will replace the Atlas V, for NASA to consider in future launch contracts until the Vulcan completed at least one successful flight, according to Tim Dunn, senior launch director at NASA's Launch Services Program.

The Vulcan rocket's first certification flight on January 8, called Cert-1, was nearly flawless, demonstrating the launcher's methane-fueled BE-4 engines built by Blue Origin and an uprated twin-engine Centaur upper stage. A second test flight, known as Cert-2, is scheduled to lift off no earlier than October 4 from Cape Canaveral Space Force Station, Florida. Assuming the upcoming launch is as successful as the first one, the US Space Force aims to launch its first mission on a Vulcan rocket by the end of the year.

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A mid-September test flight of Vulcan could permit a military launch this year

A top-down view of United Launch Alliance's first Vulcan rocket before its liftoff in January.

Enlarge / A top-down view of United Launch Alliance's first Vulcan rocket before its liftoff in January. (credit: United Launch Alliance)

United Launch Alliance is targeting September 16 for the second test flight of the new Vulcan rocket, and a flawless mission could finally set the stage for the first Vulcan launch for the US military by the end of the year.

The US Space Force has contracted ULA's Vulcan rocket to launch the majority of the military's space missions over the next few years. Pentagon officials are eager for Vulcan to get flying so they can start checking off a backlog of 25 military space missions the Space Force wants to launch by the end of 2027.

By any measure, the first Vulcan launch in January was a resounding success. On its debut flight, the new rocket delivered a commercial lunar lander to an on-target orbit. The next Vulcan mission, which ULA calls Cert-2, will be the rocket's second certification flight. The Space Force requires ULA to complete two successful flights of the Vulcan rocket before entrusting it to launch national security satellites.

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Rocket Report: China flies reusable rocket hopper; Falcon Heavy dazzles

SpaceX's 10th Falcon Heavy rocket climbs into orbit with a new US government weather satellite.

Enlarge / SpaceX's 10th Falcon Heavy rocket climbs into orbit with a new US government weather satellite. (credit: SpaceX)

Welcome to Edition 6.50 of the Rocket Report! SpaceX launched its 10th Falcon Heavy rocket this week with the GOES-U weather satellite for NOAA, and this one was a beauty. The late afternoon timing of the launch and atmospheric conditions made for great photography. Falcon Heavy has become a trusted rocket for the US government, and its next flight in October will deploy NASA's Europa Clipper spacecraft on the way to explore one of Jupiter's enigmatic icy moons.

As always, we welcome reader submissions, and if you don't want to miss an issue, please subscribe using the box below (the form will not appear on AMP-enabled versions of the site). Each report will include information on small-, medium-, and heavy-lift rockets as well as a quick look ahead at the next three launches on the calendar.

Sir Peter Beck dishes on launch business.Β Ars spoke with the recently knighted Peter Beck, founder and CEO of Rocket Lab, on where his scrappy company fits in a global launch marketplace dominated by SpaceX. Rocket Lab racked up the third-most number of orbital launches by any US launch company (it's headquartered in California but primarily assembles and launches rockets in New Zealand). SpaceX's rideshare launch business with the Falcon 9 rocket is putting immense pressure on small launch companies like Rocket Lab. However, Beck argues his Electron rocket is a bespoke solution for customers desiring to put their satellite in a specific place at a specific time, a luxury they can't count on with a SpaceX rideshare.

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ULA will launch its second Vulcan rocket without a real payload

United Launch Alliance's first Vulcan rocket on the launch pad before liftoff in January.

Enlarge / United Launch Alliance's first Vulcan rocket on the launch pad before liftoff in January. (credit: United Launch Alliance)

The second flight of United Launch Alliance's Vulcan rocket will take off in September with a dummy payload in place of Sierra Space's Dream Chaser spaceplane, preserving a chance for ULA to begin launching US military satellites on the new rocket by the end of the year, officials announced Wednesday.

Tory Bruno, ULA's CEO, announced the change in flight plan for the second Vulcan rocket in a conference call with reporters. There was little hope Sierra Space's Dream Chaser would be ready to make its first resupply run to the International Space Station before the end of the summer.

Dream Chaser had been booked to launch on the second test flight of ULA's Vulcan rocket for the last five years. With the near-flawless inaugural flight of Vulcan in January and a successful second flight later this year, ULA's Vulcan will be certified by the US Space Force to loft the military's most sensitive national security satellites into orbit.

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Blue Origin joins SpaceX and ULA in new round of military launch contracts

Blue Origin's New Glenn rocket on the launch pad for testing earlier this year.

Enlarge / Blue Origin's New Glenn rocket on the launch pad for testing earlier this year. (credit: Blue Origin)

After years of lobbying, protests, and bidding, Jeff Bezos's space company is now a military launch contractor.

The US Space Force announced Thursday that Blue Origin will compete with United Launch Alliance and SpaceX for at least 30 military launch contracts over the next five years. These launch contracts have a combined value of up to $5.6 billion.

This is the first of two major contract decisions the Space Force will make this year as the military seeks to foster more competition among its roster of launch providers and reduce its reliance on just one or two companies.

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