NASA: Engine Defects Behind Antares Rocket Explosion

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Faulty design and manufacturing of engine components were among likely causes of the Orbital Sciences rocket explosion a year ago, according to a report (PDF) this week from a NASA-appointed review team. The unmanned Antares rocket, carrying cargo to the International Space Station, exploded at a commercial launch site in Virginia on Oct. 28, 2014. The independent review team’s findings showed three possible factors in the explosion: a design weakness in part of the AJ26 engine’s turbopump, a manufacturing defect in the turbopump, and possible damage from foreign object debris. The rocket was intentionally destroyed when operators detected a malfunction about 15 seconds after liftoff.

The review team reported that rotating and stationary parts within one engine’s turbopump were rubbing together, resulting in a fire. It also found a “manufacturing or other workmanship defect” in the turbopump, but added that further inspections would be required to determine if this would cause consistent engine failures. As for the titanium and silica FOD found in the engine, the report said it’s one possible factor, but “no firm conclusions can be drawn.”The Antares rocket launch was Orbital Sciences’ third under an eight-launch contract with NASA worth $1.9 billion. The company plans to resume Antares missions in 2016 with different engines. Meanwhile, NASA is preparing for a launch of Orbital Sciences’ Cygnus cargo spacecraft in December, using a United Launch Alliance Atlas V rocket. It will be Cygnus’ first liftoff from Cape Canaveral.

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