Author Topic: Orion Discussion Thread 2  (Read 561592 times)

Offline Eric Hedman

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Re: Orion Discussion Thread 2
« Reply #900 on: 01/01/2026 06:12 am »


Getting around this OMS-E nozzle would be a piece of cake.
Why would you have to?  If you launch Orion on a different rocket than SLS, you will have to design a new adapter to connect to that rocket's upper stage.  Leave the adapter on and have the tug dock to it.  It has to be able to handle launch loads so it will be strong enough.  Or make the upper stage refuelable, and leave it attached to Orion and refueling it to just take Orion out to the Moon with the upper stage attached.

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Re: EM-2/Artemis 2 Orion Construction and Processing Updates
« Reply #901 on: 01/09/2026 08:31 pm »
I have a bad feeling about this because Charles Camarda was still critical of the decision. Is this the same heat shield from Artemis I?
« Last Edit: 01/09/2026 08:33 pm by tigerdude9 »
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Offline catdlr

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Re: Re: EM-2/Artemis 2 Orion Construction and Processing Updates
« Reply #902 on: 01/09/2026 09:30 pm »

I have a bad feeling about this because Charles Canada was still critical of the decision. Is this the same heat shield from Artemis I?

This is a new item, not reused, although it features the same design. The flight dynamics are being modified during reentry to prevent (or at least mitigate) this issue. This matter has been discussed earlier in this thread.

Start here and proceed down to the end of the thread.
https://forum.nasaspaceflight.com/index.php?topic=38410.msg2589059#msg2589059
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A golden rule from Chris B:  "focus on what is being said, not disparage people who say it."

Offline deltaV

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Re: Orion Discussion Thread 2
« Reply #903 on: 01/10/2026 01:48 am »
Charles Camarda responds to the the Eric Berger article on Orion's heat shield.

Quote from: Charles Camarda
1/9/2026 1:48PM PT - https://www.linkedin.com/posts/charlescamarda_nasa-artemisheatshield-orionheatshield-activity-7415490596121067520-ZtzE
My response to Eric Berger:

Sorry Eric, what you perceived were my feelings of "being disrespected" were actually feelings of outrage at what I was witnessing.  Some of the exact same people responsible for failing to understand the shortcomings of the Crater Analysis tool (used tiny pieces of foam impacts to Shuttle tiles predict a strike from a piece of foam which was 6000 larger and which caused the Columbia Accident) were on the Artemis Tiger Team now claiming they could predict the outcome of the Orion heatshield using a tool  (similar to CRATER) called the Crack Identification Tool (CIT) which was also not physics based and relied on predictions of the key paramenter, permeability, which they claim to be the "root" cause, pressure, to vary by three orders of magnitude (thats over 1000x).  I guess the fact that the you, the Artemis Program Tiger Team and the IRT missed this minutiae and the fact that they were using this tool to predict failure and risk was not important to note.

You also missed that the only person to create a true multiphysics analysis to try to predict spallation, Dr. Stephen Scotti,  stated that his code could only predict cracking and not spallation and could not be used quantatively, only qualitatively (hopefully I dont have to explain to you what that means).

The rage you witnessed was my observing the exact behaviors used to construct of risk and flight rationale which caused both Challenger and Columbia Accidents. Using "tools" inappropriately and then claiming results to be "Conservative."  Not to mention the reliance on Monte Carlo simulations to predict failure probabilities which were also proven to be innacurate by orders of magnitude in my book "Mission Out of Control" which you claim to have read.

I suggest, in the spirit of transparency, you should ask NASA to release just the "Findings" of NESC Report TI-23-01849 Volume I. Finding 1 states the analysis cannot accurately predict crack initiation and propagation at flight conditions. And there was so much more which was conveniently not presented.

I hope Jared understands what a challenging job he will have trying to fix the culture at NASA.  If those are the people he is relying on to keep our crews safe, our only hope is to have faith in God and pray.  I hope Jared sees the issues and will have the courage to do what is necessary.

Otherwise, a good attempt at "journalism."

His Wikipedia article (https://en.wikipedia.org/wiki/Charles_Camarda) says he has a PhD in Aerospace Engineering, professional experience with heat shields, was an astronaut and the Director of Engineering at NASA's Johnson Space Center.

His social skills leave something to be desired right now, possibly because he's angry. However this isn't evidence he's wrong. IIRC the engineer who predicted the Challenger disaster, https://en.wikipedia.org/wiki/Roger_Boisjoly, also had some social skills weaknesses. The people with the best social skills probably instinctively go along with group think without realizing it so we need to listen to people like this.

My hunch is that Orion will probably come home just fine, but NASA claims to be aiming for better safety than "probably", so NASA should get an independent team (I mean outside of NASA) with actual funding to investigate this.
« Last Edit: 01/10/2026 01:57 am by deltaV »

Online DanClemmensen

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Re: Orion Discussion Thread 2
« Reply #904 on: 01/10/2026 02:27 am »
My hunch is that Orion will probably come home just fine, but NASA claims to be aiming for better safety than "probably", so NASA should get an independent team (I mean outside of NASA) with actual funding to investigate this.
Too late. Someone in the chain of command should have done this the instant they saw the pictures of the damage to the Artemis I Orion heat shield, some time in late 2022. Each individual in that chain of command, up to and including Administrator Bill Nelson, should have made this decision.

Sadly, the juggernaut trundled along, becoming ever more unstoppable. Nobody can stop it now, and Artemis II will launch with crew aboard. I truly hope that the worst does not occur and the crew returns safely. This is the highest probability.
« Last Edit: 01/10/2026 03:43 am by DanClemmensen »

Offline Oberon_Command

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Re: Orion Discussion Thread 2
« Reply #905 on: 01/10/2026 03:08 am »
His social skills leave something to be desired right now,

How so?

Offline deltaV

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Re: Orion Discussion Thread 2
« Reply #906 on: 01/10/2026 05:57 pm »
His social skills leave something to be desired right now,

How so?

"(hopefully I dont have to explain to you what that means)", "which you claim to have read", and "Otherwise, a good attempt at "journalism."" were undiplomatic, insulting Eric Berger for no reason.

Offline Mythundare

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Re: Orion Discussion Thread 2
« Reply #907 on: 01/12/2026 01:27 am »
His social skills leave something to be desired right now,

How so?

"(hopefully I dont have to explain to you what that means)", "which you claim to have read", and "Otherwise, a good attempt at "journalism."" were undiplomatic, insulting Eric Berger for no reason.

Yeah, those were just him venting. I get why though, as Berger's article kinda made it seem like Camarda was an angry old man who just wanted to be in the room.

Camarda brought up 3 specific points: the Crack Identification Tool shouldn't be trusted, that Scotti's analysis couldn't predict spalling by Scotti's own statement, and that an NESC report's finding was that "the analysis" (unclear which analysis) cannot accurately predict crack initiation and propagation at flight conditions. So if those were the basis of the decision that it was safe, and Camarda's criticism is accurate, then that seems to be a brittle foundation.

He also claims there is "so much more which was conveniently not presented". I'm wondering how Camarda had so much more information if the agency is keeping him at arm's length.
« Last Edit: 01/12/2026 01:28 am by Mythundare »

Offline deltaV

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Re: Orion Discussion Thread 2
« Reply #908 on: 01/12/2026 01:57 am »
He also claims there is "so much more which was conveniently not presented". I'm wondering how Camarda had so much more information if the agency is keeping him at arm's length.

He used to be Director of Engineering at JSC. He likely knows people who unofficially showed him additional materials.

Online tigerdude9

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Re: Re: EM-2/Artemis 2 Orion Construction and Processing Updates
« Reply #909 on: 01/13/2026 03:48 pm »

I have a bad feeling about this because Charles Canada was still critical of the decision. Is this the same heat shield from Artemis I?

This is a new item, not reused, although it features the same design. The flight dynamics are being modified during reentry to prevent (or at least mitigate) this issue. This matter has been discussed earlier in this thread.

Start here and proceed down to the end of the thread.
https://forum.nasaspaceflight.com/index.php?topic=38410.msg2589059#msg2589059

I highly doubted NASA would reuse a heat shield. I just wanted to make sure. Anyway, my concern is the outcome of this decision. I have the following scenarios:

I am not taking sides with anyone.

1. The issue is prevented or mitigated and Charles stand corrected.
2. Orion is damaged to the same extent of that of Artemis I, but not enough to cause danger to the crew.
3. More damage than Artemis I, but still not enough to cause danger to the crew.
4. More damage than Artemis I and is enough damage to cause danger to the crew.
5. Catastrophic damage that results in Orion disintegrating during reentry and the crew perishes.

I think the first or second option is the most likely. The heatshield should hold out and do it's job.
Also Charles disagrees with Jared:
https://x.com/charliecamarda/status/2011010429800124526?s=46
« Last Edit: 01/15/2026 02:12 pm by tigerdude9 »
Launch director NTD, your launch team is ready to proceed.

Offline Chris Huys

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Re: Orion Discussion Thread 2
« Reply #910 on: 01/18/2026 08:34 pm »
Charlie, wrote a second article on his linkedin, on the nasa's orion heat shield deficiencies issue.

https://x.com/CharlieCamarda/status/2011770140690468906?s=20
Quote
Totally agree with taking risks and the importance of exploration. But when you do not even understand the “failure mechanism”, cannot predict failure quantatively by analysis/test correlation, and cannot even bound the problem; you cannot make unfounded claims like your results are “conservative” and your “operational workarounds” actually mitigate the problems.

I was able to find major technical issues and false statements in a short 3-hour briefing presenting only the program side of the story and 1 day being allowed to review some of the technical issues that made me very troubled.

I can prove how much the program does not know and how similar simplified analysis methods caused Challenger and Columbia. Only one retired research engineer attempted to develop a coupled full physics-based analysis and he could not predict spallation.

If I had time, I would use AI to digest as much information as I was allowed to skim through and it would have given a much better risk posture and assessment of flight rationale than what is being foisted on the unknowing public.

Not to mention that the very little we learn about the Heatshield on the Artemis II mission will be of very little use for Artemis III. We will be flying a different material system (porous AVCOAT), possibly a different trajectory, and who knows what else is different! And we are not even sure SLS will be part of the new Lunar architecture.

So the question is, why do we have to have a crew? Or, more importantly was not having a crew even an option. There are other inexpensive ways to flight test without a crew.

I think, charlie , is right. We shouldnt fly crew on artemis II. The day and age of workarounds after 2 years of study are over. SpaceX showed that they can resolve issues in 6 months. Nasa, should have done the same.

Online Vultur

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Re: Orion Discussion Thread 2
« Reply #911 on: 01/19/2026 04:11 am »
I think part of the point is testing the ECLSS with actual people? So a LEO flight test with crew (less stress on the heat shield) might be better than an Artemis I repeat. Apollo did LEO with crew before going to the Moon.

I really don't think the plan will change at this point, though.

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Re: Orion Discussion Thread 2
« Reply #912 on: 01/19/2026 01:00 pm »
I noticed the astronauts still wearing the orange Space Shuttle lunch entry suits

Online eeergo

Re: Orion Discussion Thread 2
« Reply #913 on: 01/19/2026 01:45 pm »
Charlie, wrote a second article on his linkedin, on the nasa's orion heat shield deficiencies issue.

https://x.com/CharlieCamarda/status/2011770140690468906?s=20
Quote
Totally agree with taking risks and the importance of exploration. But when you do not even understand the “failure mechanism”, cannot predict failure quantatively by analysis/test correlation, and cannot even bound the problem; you cannot make unfounded claims like your results are “conservative” and your “operational workarounds” actually mitigate the problems.

I was able to find major technical issues and false statements in a short 3-hour briefing presenting only the program side of the story and 1 day being allowed to review some of the technical issues that made me very troubled.

I can prove how much the program does not know and how similar simplified analysis methods caused Challenger and Columbia. Only one retired research engineer attempted to develop a coupled full physics-based analysis and he could not predict spallation.

If I had time, I would use AI to digest as much information as I was allowed to skim through and it would have given a much better risk posture and assessment of flight rationale than what is being foisted on the unknowing public.

Not to mention that the very little we learn about the Heatshield on the Artemis II mission will be of very little use for Artemis III. We will be flying a different material system (porous AVCOAT), possibly a different trajectory, and who knows what else is different! And we are not even sure SLS will be part of the new Lunar architecture.

So the question is, why do we have to have a crew? Or, more importantly was not having a crew even an option. There are other inexpensive ways to flight test without a crew.

I think, charlie , is right. We shouldnt fly crew on artemis II. The day and age of workarounds after 2 years of study are over. SpaceX showed that they can resolve issues in 6 months. Nasa, should have done the same.

First red flag: very vocal single guy with loud, insistent theory opposed to consensus position.
This alone could also be a green flag though: there are many instances of single heroes going against the tide for the right reasons, with fully rigorous arguments, starting with the oft-cited Columbia/Challenger. However...

Second red flag: diametric opposition to consensus position, not looking for compromises or intermediate "good enough" proof, based on the impossibility to prove a negative (heat shield is NOT safe). Only his approach is valid.
Third red flag: lack of constructive alternative to move forward, beyond just stopping everything.
Fourth red flag: overstressing jargon ("physics-based", without much explanation of what it means in practice) over contentious concepts explained in plain language.
Fifth red flag: no merit given to the consensus approach, providing only top-down critique of the full method, and lack of identification of relevant weaknesses. Note that full ab-initio prediction of each and every phenomenology should not be necessary, unless the effects have a credible safety impact.
Sixth red flag: "I would ask AI [...] much better risk posture and flight rationale". I think this one is self-explanatory, and reeks of armchair tinfoil.
Seventh red flag: lack of engineering approach, appeal to esoterism ("who knows what else will be different!")
Eighth red flag: Freudian slip ("we are not even sure SLS will be part of the future Lunar Architecture"). If you want to make sure Orion works during reentry, SLS is immaterial. If you want to make sure Orion works, future changes in 5-10 years' time are irrelevant to your engineering task. Unless of course you're clinging to the only issue of note derived from Artemis I, the heat shield exhaustively-studied nothingburger, to advance a multi-pronged cancellation agenda favored by certain ideologues.

Yeah, the green flag is almost invisible behind the red banners.

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Re: Orion Discussion Thread 2
« Reply #914 on: 01/19/2026 05:47 pm »
Why didn"t NASA use a new THICKER heat shield ?

Online DanClemmensen

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Re: Orion Discussion Thread 2
« Reply #915 on: 01/19/2026 06:07 pm »
Why didn"t NASA use a new THICKER heat shield ?
The existing shield is thick enough if there is no spalling. A thicker shield cannot be shown to be thick enough unless you know the characteristics of the spalling. In particular, based on the design and analyses done prior to Artemis I, the existing shield should not have exhibited any spalling. Based solely on looking at the publicly-available images and with zero professional expertise, the Artemis I shield did not have excessive char loss. In that regard is performed as expected. The problem was spalling, not ablative char loss. For all we non-experts know, a thicker shield might result in larger chunks being spalled off.

Online DanClemmensen

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Re: Orion Discussion Thread 2
« Reply #916 on: 01/23/2026 03:25 pm »
Excellent CNN article on the Artemis II heat shield decision. This is the best article I have seen in the general press and is a better overview than I have seen even in the more space-oriented press.
   https://www.cnn.com/2026/01/23/science/artemis-2-orion-capsule-heat-shield

Offline Chris Huys

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Re: Orion Discussion Thread 2
« Reply #917 on: 01/24/2026 10:54 am »
Excellent CNN article on the Artemis II heat shield decision. This is the best article I have seen in the general press and is a better overview than I have seen even in the more space-oriented press.
   https://www.cnn.com/2026/01/23/science/artemis-2-orion-capsule-heat-shield

CNN article shows that charlie is not alone in his resistance to allow crew on artemis II.

Quote
NASA said in its Friday statement. And the adjusted return path is designed to create “a steeper descent angle to reduce exposure time at peak heating, thus minimizing further char loss.”

“This thorough testing, analysis, simulation, and expert validation collectively formed NASA’s official flight rationale providing sufficient justification to proceed without redesigning the heat shield,” the statement reads.

Other experts, however, disagree that changing Orion’s flight path is enough to guarantee that the crew will make it home safely.

“The reason this is such a big deal is that when the heat shield is spalling — or you have big chunks coming off — even if the vehicle isn’t destroyed, you’re right at the point of incipient failure now,” said Dr. Dan Rasky, an expert on advanced entry systems and thermal protection materials who worked at NASA for more than 30 years.

“It’s like you’re at the edge of the cliff on a foggy day,” Rasky said.

Rasky, like Camarda, does not believe that NASA should allow astronauts to fly on board the Artemis II Orion capsule.

Charlie also published a letter he wrote to NASA administrator Jared Isaacman.

https://x.com/CharlieCamarda/status/2014442699898703951

Quote

The link it a letter I wrote to NASA Administrator, Jared Isaacman.  it was an impassioned plea to reverse couse, show true leadership and do what is necessary to return to a true research culture at NASA:

The letter is on google docs.
https://docs.google.com/document/d/1fPF_LnZhb4VRl4q2x-WBc-nYObk0cEAE/edit

Quote
A Letter to NASA Administrator Jared Isaacman
Subject: Opportunity to Save Astronaut Lives, NASA, and the U.S. Space Program

By Dr. Charles Camarda

I have slept very little since the Artemis heat shield meeting in Washington, D.C., on January 8, 2025. What I observed during that meeting was significantly worse than I had anticipated, even prior to receiving detailed information and relying only on my professional intuition, my background in research engineering, and more than fifteen years of study in organizational behavior and accident-causation mechanisms.

My concerns were intensified by the extremely limited time available to review the NESC and IRT reports, followed by a three-hour data exchange that was largely framed and presented by the Artemis Program Tiger Team. These constraints prevented a truly independent technical assessment and reinforced organizational patterns I have seen repeatedly in the lead-up to past aerospace failures.

More than three years ago, I formally requested a proper and truly independent external tiger team review—composed of researchers and scientists from NASA, government laboratories like Sandia, and academia. That request was denied by then-senior NASA Leadership. I therefore appreciate your decision to allow me to be briefed by the Artemis team this past Thursday.

I am writing to provide you with this assessment because we are rapidly approaching the launch of Artemis II, and the technical and organizational issues associated with the Orion heat shield represent a serious risk.

Based on the information available to me, I can state the following with high confidence:

1. The Artemis Program does not understand the root cause or true failure mechanisms that led to heat shield spallation on Artemis I.

The program cannot predict failure for even small arc-jet and radiant heating test samples (12- to 24-inch scale), let alone for the full-scale 16.5-foot diameter Orion heat shield because it is not using a validated, integrated multi-physics analysis.

The Crack Indicator Tool (CIT), which has not been thoroughly reviewed and validated by external subject matter experts, is claimed to be physics-based and conservative. In my judgment, it is neither. Its predictive capability lies somewhere between the crude CRATER tool used to predict damage for the Columbia accident and the slightly better
Mark Salita model used for the Challenger accident and may be inaccurate by orders of magnitude. As such, it cannot predict the true failure mechanism, which is most likely related to crack initiation, crack propagation, and other mechanisms that lead to spallation.

If you cannot validate the failure mechanism , as stated above, you cannot predict with any certainty that the steps you claim will mitigate the problem (e.g., the trajectory modification) aren’t actually exacerbating the problem and/or causing other unintended consequences.

2. Decision-making has relied on a single internally controlled narrative.

The briefing and supporting material reflected almost exclusively the Artemis Program Tiger Team’s perspective. I place very little confidence in the IRT report, as it did not perform any independent analysis and did not even recognize or challenge the claim that root cause had been demonstrated through physics-based methods.

3. NASA lacks sufficient independent multi-physics expertise applied to this problem.

Only one individual at NASA conducted a true multi-physics analysis, he stated at the meeting for all to hear, that it was only qualitative and not able to predict the failure mechanism, spallation. Three years ago, I proposed forming a multidisciplinary team across Sandia and NASA centers to address this. That proposal was denied by NASA leadership.

4. The NESC itself acknowledges how little is known about the true failure mechanism which is the first step in the flight rationale logic .

NESC Finding 1 states:

AVCOAT material response is dependent on time history of heating, sample dimensions, and manufacturing variability (e.g., local permeability/porosity, tamp planes) so its behavior cannot be characterized in ground testing to a degree that permits precise prediction of crack initiation and propagation at flight conditions.

When the “technical” managers in the NESC and NASA HQ could not understand what I was telling them post Columbia, I had to simplify my message and give them some warning signs to calibrate the narrative they were hearing from their internal teams. I saw many signals of dysfunctional teams during that heatshield meeting in D.C. that were related to both Shuttle accidents and the inability to understand the true failure mechanism of both prior accidents and the 8R RCC wing leading edge anomaly during and following my mission as explained in Chapter 4 of my book1.

<snip; paragraphs from his book about the shuttle accidents i couldnt cut@paste>

Conclusion

History shows accidents occur when organizations convince themselves they understand problems they do not. This issue exhibits the same patterns that preceded past catastrophes. NASA can still choose a different outcome. This is a defining moment which can set the tone for the transformation that is necessary. Every prior Administrator has passed on this opportunity!

Offline Chris Huys

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Re: Orion Discussion Thread 2
« Reply #918 on: 01/24/2026 12:25 pm »
Also in the recent flame trench episode from nsf,



, ej is not happy with the flight rationale behind flying crew on artemis II.

Discussion, begins at 39minutes and ends around 1h16 minutes, into the youtube vid. ej is concerned that making the blocked avcoat more permeable will not solve all issues. And he points to the rusty colors of the seams of the blocked avcoat on the left side of the artemis I capsule at the time it came back. Pointing that that looks like the underlaying backing plate, not part of the heat shield, was getting burned.

1h6m in the youtube vid, were ej gets a bit spicy about the heat shield issues of orion.

(there was also a argument, that flight rationale caused partial degraded o-ring on one  of the space shuttles, to not be a concern that needs to be fixed immediately, like it is now with a bit burned backplate)

Offline Bob Shaw

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Re: Orion Discussion Thread 2
« Reply #919 on: 01/24/2026 01:40 pm »
I have to say that I found the mere fact that the NASA OIG had to be the whistleblower regarding the Artemis I damage really disturbing. It suggested another failure of NASA’s safety culture. I hope the crew survive their flight but it won’t surprise me if they don’t.
« Last Edit: 01/24/2026 01:40 pm by Bob Shaw »

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