LNG: TESLARATI

Six weeks after the spacecraft completed its orbital launch debut, SpaceX’s first flight-proven Crew Dragon capsule suffered a catastrophic explosion seconds before a planned SuperDraco test fire.

In the last nine years, SpaceX has successfully built, tested, launched, and recovered Cargo and Crew Dragons 18 times, including five instances of Cargo Dragon capsule reuse, all with minor or no issues. The April 20th event is the first time in the known history of SpaceX’s orbital spacecraft program that a vehicle – in this case, the first completed and flight-proven Crew Dragon capsule – has suffered a total failure. Regardless of the accident investigation’s ultimate conclusions, the road ahead of Crew Dragon’s first crewed test flight has become far more arduous.

According to information acquired by NASASpaceflight.com, SpaceX was in the middle of a series of static fire tests meant to verify that the flight-proven capsule was in good working order after Crew Dragon’s inaugural mission to orbit. The spacecraft was to be tested near SpaceX’s Cape Canaveral Landing Zone facilities, where the company has a small but dedicated space for Dragon tests. Crew Dragon C201’s testing began earlier on Saturday, successfully firing up its smaller Draco maneuvering thrusters. This transitioned into a planned SuperDraco ignition, what would have been the first such integrated test fire for capsule C201.

SpaceX planned to rapidly reuse Crew Dragon C201 for an upcoming in-flight abort (IFA) test, in which the spacecraft would be required to successfully escape from Falcon 9 at the point of peak aerodynamic stress (Max Q). Based on a leaked video of the failure, one or several faults in Crew Dragon’s design and/or build led to a near-instantaneous explosion that destroyed the spacecraft. Sound in the background seems to indicate that the explosion occurred several seconds before the planned SuperDraco ignition, a major concern given their pressure-fed design.

As pressure-fed rocket engines specifically designed to be the basis of a launch escape system, Crew Dragon and its SuperDraco thrusters are meant to be ready to ignite at a millisecond’s notice once they are armed in a flight-ready configuration. It’s safe to say that ten seconds away from a specifically planned ignition is one of those moments, although there is a limited chance that SpaceX’s static fire procedures intentionally diverge from an abort-triggered ignition. Regardless, the fact that Crew Dragon was destroyed before the ignition of its SuperDracos is not an encouraging sign.

Instead of a problem with its high-performance abort thrusters, it can be tentatively concluded that Crew Dragon’s explosion originated in its fuel tanks or propellant plumbing. Such an immediate and energetic explosion points more towards a total failure of propellant lines or valves (or their avionics), while another – and potentially far more concerning – cause could be one of Crew Dragon’s pressure vessels. In a space as enclosed as a Dragon capsule, the rupture of a pressure vessel could trigger a chain reaction of pressure vessel failures, freeing both oxidizer (NTO) and fuel (MMH). Known as hypergolic propellant, NTO and MMH ignite immediately (and violently so) when mixed.

It’s quite possible that the accident investigation to follow will be SpaceX’s most difficult and trying yet. Regardless of the specific cause, the footage of Crew Dragon C201’s demise does not support any positive conclusions about the fate of astronauts or passengers, had they been aboard during the violent explosion. Seemingly triggered in some way by the very system meant to safely extricate Crew Dragon and its astronauts from a failing Falcon 9 rocket, major work will need to be done to prove to NASA that the spacecraft is safe. Sadly, Boeing’s Starliner spacecraft – funded in parallel with Crew Dragon under NASA’s Commercial Crew Program – suffered a far less severe but no less significant failure during a static fire test of its own abort thrusters. Boeing was forced to remove the impacted hardware from its flight plans to extensively clean, repair, and rework the service module.

NASA is now faced with the fact that both of the spacecraft it supported with CCP have exhibited major failures related to their launch escape systems. Crew Dragon’s catastrophic explosion comes as a particularly extreme surprise given how extensively SpaceX has already tested the SuperDraco engines and plumbing, as well as the successful completion of the spacecraft’s launch debut. In the process of DM-1 launch preparations, Crew Dragon likely spent a minimum of 80 minutes with its SuperDraco thrusters and propellant systems primed and ready to abort at any second, apparently without a single mildly-concerning issue.

Godspeed to SpaceX and NASA as they enter into this challenging and unplanned failure investigation.

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Tesla has released a short video showcasing the next-generation Roaster’s blisteringly quick 0-60 mph acceleration of 1.9 seconds. “Zero to sixty faster than you can read this caption,” the all-electric car manufacturer posted on Twitter with video clip challenging viewers to do just that.

Once in production, next-gen Roadster owners will enjoy several performance advantages beyond acceleration including a 250+ mph top speed and 620 miles of battery range. All-wheel drive, 10,000 Nm of wheel torque, and a quarter mile time of 8.8 seconds also make the list of what’s included. Even with all those features packed in for track-level performance, the Roadster will still include seating for four. Perhaps even more amazingly, the next-gen Roadster will be offered at the relatively bang-for-the-buck base price of $200,000.

Zero to sixty faster than you can read this caption – https://t.co/ELg96rZfIq pic.twitter.com/4EFV9CvG8o

— Tesla (@Tesla) April 19, 2019

Tesla recently announced that all of its vehicles will include Autopilot as a standard feature, but the Roadster will have an additional “Augmented Mode” to enhance human driving ability.

“Definitely. Will also have Augmented Mode that will massively enhance human driving ability. Like a flying metal suit, but in car form …,” Tesla CEO Elon Musk said via Twitter in response to an Autopilot inquiry last year, drawing references and comparisons to Marvel’s Iron Man and Tony Stark. Musk has additionally teased that a SpaceX package will be available for purchase, enabling the Roadster to hover similar to the DeLorean of Back to the Future fame.

The Roadster was designed as a “hardcore smackdown” to gasoline cars, and with the current spec sheet, the all-electric supercar certainly looks like it will fulfill its purpose. The performance levels achievable by battery-electric vehicles aren’t without detractors, however. Chief technical executives at Ferrari and Lamborghini cited the lack of multiple full-power launch capability, battery placement, and lack of engine noise and deal-breakers for investment in an all-electric supercar earlier this year despite the existence of several fully electric supercars already setting new track records such as the NIO EP9.

Tesla isn’t planning on delivering next-gen Roadsters to customers until 2020, but the fan community hasn’t let that time frame stop them from dreaming about a Roadster-packed future. One graphics-savvy fan created and shared an impressive video likening the car to light due to the breakthrough it stands to represent in the auto industry. In another instance, an automotive render specialist published a clip depicting what it would be like to encounter the next-generation Tesla Roadster on the road in a drive-by fan video. Meanwhile, successful referral program participants are eagerly awaiting their Founders Series Roadsters won prior to Tesla’s reboot of the contest.

A recent flyby over Tesla’s Gigafactory 1 site in Nevada has shown that the electric car maker’s expansive battery factory has been fitted with additional solar panels. The new additions to the facility’s solar array are rather few, hinting at what appears to be a deliberate effort to focus Gigafactory 1’s improvements from within.

Images of Gigafactory 1 from August 2018 show that most of the existing solar panels on the facility’s roof were already installed. Compared to aerial images obtained by Teslarati on April 18, the extensions to Gigafactory 1’s solar array are rather few. Tesla has mostly focused on boosting Gigafactory 1’s production numbers over the past year, particularly when it comes to the battery cells for the Model 3.

Following recent reports alleging that Panasonic is freezing its investments in Gigafactory 1, Tesla has stated that it is working on optimizing its existing lines in the facility to increase output. In a statement, a Tesla spokesperson noted that while it will continue to make new investments in the factory, adding that “we think there is far more output to be gained from improving existing production equipment than was previously estimated.”

Gigafactory 1 is a key component for Tesla’s operations. Being a facility that is designed from the ground up by Tesla, the company has been able to adopt some unique design elements for Gigafactory 1. These include, among other things, the lack of a natural gas line within the facility, having a roof that is optimized for solar panel installation, and using natural processes to generate dry air. Tesla is also using a chilled water plant to generate a surplus of cold water naturally at night to provide cooling needs during the day.

With these in place, Gigafactory 1 is set to become not only one of the world’s largest buildings; it will also be one of the world’s most sustainable once complete. One can only hope that with Tesla Energy’s expected ramp this year, Gigafactory 1’s roof will soon be covered by solar panels, similar to the company’s Tilburg assembly plant in the Netherlands. Tesla has installed a 3.4 MW solar array on the Tilburg site, generating enough electricity to meet the facility’s needs throughout most of the year.

The Audi e-tron, once dubbed by avid Tesla critics as a potential “Tesla Killer,” is reportedly running into production problems due to a constrained supply of batteries and a slower-than-expected delivery of electric motors. These production problems have reportedly caused Audi to postpone the release of its upcoming all-electric car, the e-tron Sportback, to 2020, roughly a year later than its intended 2019 release date.

Sources familiar with the activities in Audi’s Brussels plant have told The Brussels Times that the German carmaker is currently being constrained by LG Chem, which supplies the e-tron’s batteries. LG Chem is the supplier of choice for a number of electric vehicles, such as the Porsche Taycan and the Jaguar I-PACE. The local publication’s sources claim that LG Chem is pushing up prices, resulting in Audi having to compete with rival automakers like BMW and Mercedes-Benz to acquire batteries for the e-tron.

This is but half of the e-tron plant’s current issues, according to the Times‘ sources. Audi is reportedly seeing delays in the deliveries of the e-tron’s electric motors as well. The SUV’s electric motors are delivered from an Audi plant in Györ, Hungary, whose workers participated in a strike earlier this year. As a result of these issues, the Brussels plant has reportedly shortened its operations to just 6 hours a day to match production to parts availability. The sources claimed that Audi will likely shift the plant to a 4-day work week in the near future.

It is unfortunate to see Audi encountering production issues with the e-tron, its first all-electric vehicle. Audi is one of the auto industry’s biggest names, having been founded in 1909. Despite its extensive experience in building cars, the company has proven to not be immune to the difficulties of electric car production, something that younger companies such as Tesla have been dealing with for years. Prior to the e-tron’s launch, the vehicle was hyped by Tesla critics as a potential “Tesla Killer,” citing, among other things, Audi’s experience in car manufacturing. As the company is learning now, it appears that building electric cars might not be as easy as Tesla skeptics would think.

Mass producing electric cars is something that Tesla continues to learn. After a gruelling “production hell” with the Model 3, Tesla has arguably become one of the most experienced electric car makers in the auto industry despite its young age. This has allowed the company to have enough foresight to secure the supply of batteries (at least to a large degree) for its electric vehicles, as represented by Gigafactory 1 in Nevada. The company has also opted for a notable degree of vertical integration, producing its vehicles from the ground up using hardware and software that were developed in-house.

The Audi e-tron is equipped with two electric motors that deliver a total power output of 300 kW, as well as a sizable 95 kWh battery that delivers and EPA rating of 204 miles of range on a full charge. The e-tron is no slouch as well, being capable of sprinting from 0-60 mph in 5.5 seconds in “Boost” mode. The all-electric SUV is expected to start deliveries in the United States next month, though it remains unsure if there will be delays due to the company’s reported issues in the Brussels plant.