SpaceX’s Falcon 9 Encounters Uncommon Setback in Orbit While Deploying Starlink Satellites

SpaceX’s Falcon 9 rocket stands as a paragon of launch vehicle reliability, yet even the stalwarts face setbacks. Such was the case on a Thursday evening when an unforeseen glitch in the rocket’s second stage emerged during an otherwise standard dispatch of a group of Starlink internet satellites. 

Elon Musk, the visionary behind SpaceX, revealed on his X platform that a mishap occurred when the Merlin Vacuum engine on the second stage failed to ignite a second time, leading to a “RUD” — industry jargon for a violent, unplanned disintegration. Although the 20 Starlink satellites reached space, their insertion into an incorrect orbit casts doubt on their ability to counteract Earth’s gravitational pull in time.

“Engineering challenge during upper stage restart to boost perigee led to an engine RUD, with the cause presently elusive,” Musk disclosed. “Our team is delving into the data this evening to ascertain the failure’s origin. Despite successful deployment, the satellites’ perigee might be excessively low for orbit adjustment. More insights expected shortly.” 

The Starlink 9-3 mission took off from Vandenberg Space Force Base in California at 7:35 p.m. PST, with the live feed later showcasing unexpected ice accumulation atop the engine. This phenomenon, highlighted by sizable chunks detaching into the engine’s exhaust, hints at a potential liquid oxygen leak. This substance, alongside kerosene, forms the rocket’s fuel, yet the precise cause of the malfunction remains undetermined.

SpaceX subsequently reported establishing communication with five of the twenty satellites, now guiding them to elevate their orbits via onboard ion thrusters. Efforts include a software update to maximize thruster output, akin to reaching “warp 9,” as Musk humorously noted on X. He candidly expressed doubts about the success of this strategy, drawing a parallel to Star Trek’s adventurous attempts.

This incident interrupts SpaceX’s impressive sequence of 335 consecutive successful launches with its Falcon fleet, including the mighty Falcon Heavy. The tally includes 96 in 2023 and 69 in 2024, with the prior significant mishap being a 2016 explosion during pre-launch testing and an in-flight failure in 2015 where the Falcon 9’s upper stage was lost minutes post-launch.

“The FAA has taken note of the anomaly during the SpaceX Starlink Group 9-3 mission from Vandenberg Space Force Base in California on July 11,” informed a spokesperson from the FAA to TechCrunch. “The incident involved the upper stage rocket’s failure while in space, with no reported injuries or damage to public property. An investigation has been mandated by the FAA.”

This event may have implications for two upcoming manned missions: the Polaris Dawn private spaceflight funded by billionaire Jared Isaacman towards this month’s end, and a mid-August astronaut transport mission for NASA.

Update: SpaceX verified the formation of a liquid oxygen leak on the second stage, leading to the visible ice accumulation during the webcast. The team also acknowledged that the 20 Starlink satellites, situated in a low 135 kilometer orbit, are destined to re-enter the Earth’s atmosphere and disintegrate.