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February 26, 2022 04:34 pm

Analyzing the Unusual Failure of Astra's Small, Frugal Rocket Launch Vehicle

Slashdot reader XXongo writes: Astra is trying to make some of the smallest launch vehicles in history. But their most recent launch of their Rocket 3 vehicle had an unusual failure, where the second stage seemed to get stuck inside the booster stage. Hackaday analyzes the failure. From Hackaday's article:The structure, engines, avionics, and useful payload of a rocket only make up a tiny portion of its liftoff mass, while the rest is dedicated to the propellant it must expend to reach orbital velocity. That's why a Falcon 9 tipping the scales at 549,054 kilograms (1,207,920 pounds) can only loft a payload of 22,800 kg (50,265 lb) — roughly 4% of its takeoff weight. As you might imagine, there's a lower limit where there simply isn't enough mass in the equation for the hardware necessary to build a fully functional rocket. But where is that limit? That's precisely what aerospace newcomer Astra is trying to find out. Their Rocket 3 is among the smallest orbital boosters to ever fly, closer in size and mass to the German V2 of World War II than the towering vehicles being built by SpaceX or Blue Origin. Even the Rocket Lab Electron, itself an exceptionally svelte rocket, is considerably larger. The reason they're trying to build such a small rocket is of course very simple: smaller means cheaper.... Such a low ticket price would have been unfathomable a decade ago, and promises to shake up an already highly competitive commercial launch market. But naturally, Astra has to get the thing flying reliably before we can celebrate this new spaceflight milestone.... [R]ather than placing just the payload into a protective aerodynamic fairing, the entire second stage needs to be enclosed. The lower portion of the second stage is tucked into the hollow interstage, and an elongated fairing makes sure the payload and its ride to space aren't exposed to supersonic airflow in the early phases of flight.... Looking at the live video from the February 11th launch, we can clearly see the chain of events that led to the upper stage losing control and ultimately failing to enter orbit. At almost exactly three minutes into the flight the payload fairing visibly shudders, but fails to open. Four seconds later the second stage, propelled forward by a spring-loaded mechanism, slams into the fairing but fails to knock it lose. Finally, at three minutes and eleven seconds into the mission, the second stage's engine ignites while still inside the interstage. This build up of pressure blows off the fairing, but unfortunately also destabilizes the second stage and sends it tumbling. One of Astra's earlier low-cost rockets actually began its launch by travelling sideways.And Hackaday now notes that this month's mission "ended in a total loss of the vehicle and payload when the upper stage tumbled out of control roughly three minutes after an otherwise perfect liftoff from Cape Canaveral Space Force Station in Florida." But they also add an encouraging note. "Such issues aren't uncommon for a new orbital booster, and few rockets in history have entered regular service without a lost payload or two on the books."

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