A pair of U.S. astronauts who test-piloted a new Boeing spaceship in June may not fly home on the craft they rode in on.
While Boeing has conducted a variety of tests in space and on the ground to try to better understand problems with its Starliner capsule, now docked at the International Space Station, NASA apparently has been busy making contingency plans for an alternative way to bring Commander Barry "Butch" Wilmore, 61, and Sunita "Suni" Williams, 58, back to Earth.
NASA officials said they would decide whether the two would return on Starliner or Boeing's competitor, SpaceX's Dragon capsule, by mid-August. That possible shift in plans, announced during a call with reporters on Wednesday, comes after two months of the agency insisting it wasn't entertaining the idea of changing horses — or, rather, spacecraft — in midstream.
If NASA chooses to use SpaceX for Wilmore and Williams' return voyage, they would remain at the space station for at least another six or seven months. That would extend their originally planned eight-day visit to a nine-month layover and would have a cascading effect on the crew lineups for future expeditions.
"I want to reiterate we haven't made a decision yet," said Steve Stich, NASA's commercial crew program manager.
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Clues that NASA was making changes emerged one day earlier when the space agency announced through a blog post that it would be postponing its next crew launch to the space station for more "flexibility" in the schedule. That SpaceX flight, originally slated to bring four people to the station this month, will now launch no earlier than Sept. 24.
If NASA chooses to send Starliner's test pilots back with SpaceX, the decision would reduce the upcoming September launch to carrying just two passengers instead of four. It would also cut short Boeing's first human spaceflight test for Starliner, making the path forward for the spacecraft to become operational unclear.
Wilmore and Williams reached the space station on June 6, despite encountering problems with Starliner's propulsion system right before docking. The issues involved helium leaks and weak thrust, apparently the result of five of the 28 thrusters malfunctioning. The thrusters are necessary for controlling and handling the ship in space.
The team has since reactivated all but one of the faulty thrusters. Boeing has continued to run tests to try to diagnose the problems and says Starliner has more than enough helium, which is used to pressurize the thrusters, to get back home.
But one of the thruster tests conducted on a replica back on Earth revealed an issue with a Teflon seal, about the size of a pinky finger, that may be swelling and shrinking, causing a blockage in the flow of propellant.
"If we could replicate the physics in some offline testing to understand why this (seal) is heating up and extruding, and then why it's contracting, that would give us additional confidence to move forward," Stich said.
NASA did not include representatives of SpaceX or Boeing on the media call Wednesday. In its own blog post, Boeing has said it is confident that Starliner can bring the astronauts home safely.
NASA hired both Boeing and SpaceX to build spacecraft to ferry astronauts back and forth to the space station a decade ago. After the agency retired the Space Shuttle in 2011, it had to pay Russia millions of dollars to get seats for U.S. astronauts on Soyuz rockets. The goal was to establish a commercial space taxi industry in the United States so that wasn't necessary.
Though SpaceX has built and run its Dragon spaceship since 2020, Boeing's Starliner has yet to pass the testing phase.
