SpaceX Completes Heat Shield Upgrade for Starship Ahead of Critical Flight 5 Test

SpaceX has completed a significant heat shield upgrade for Starship ahead of its fifth test flight. The upgrade aims to improve reentry safety following the issues from the fourth flight. A critical static fire test is planned before the next launch.

SpaceX Prepares Starship for Flight 5 with Upgraded Heat Shield and New Static Fire Test

After removing the second-stage Starship spacecraft from its processing site on a mobile static fire stand, SpaceX is preparing for Starship flight 5. In anticipation of the fifth flight, SpaceX replaced all of the ship's thousands of heat shield modules following the fourth Starship flight last year, which was notable for its forward flap catching fire during re-entry. The ship may be preparing for a static fire attempt before the fifth test flight to complete an additional pre-flight test.

The fifth flight of SpaceX's upper-stage Starship has been in the works for an extended period. Prior to the launch of flight four early last month, SpaceX had already static-fired the ship as part of its rapid testing schedule, which is designed to reduce the time between tests. Nevertheless, the fourth flight resulted in the upper fin of the second stage catching fire. Subsequently, SpaceX initiated the replacement of all heat shield panels as part of an upgrade.

Most of the heat shield tiles on Flight 5's aircraft have been replaced, as evidenced by footage from local media. According to Wccftech, SpaceX has demolished the site where the ship's initial static fire occurred, which was on a ground pad adjacent to the launch platform. Future static fires, particularly those that affect the boat, should take place on a mobile test structure at a considerable distance from the orbital test stand on a repurposed gun ranch. The "Massey's site" is where SpaceX has previously tested its rocket tanks. The infrastructure has been substantially upgraded in the past few months to accommodate static fires.

Starship Flight 5 to Test New Heat Shield and Engine Re-Ignition at Massey's Site

The Flight 5 Starship upper stage may be the first to experience a static fire at Massey's, and the modifications include test tanks and a flame trench.

The fifth test flight will significantly impact the second stage. SpaceX's inaugural full-stack Starship flight in 2023 was plagued by several issues, including the Super Heavy booster's inability to successfully separate from the second-stage ship and its numerous engine failures. To resolve the stage separation issue, SpaceX implemented an interstage ring on the booster. Subsequent tests have demonstrated minimal engine failures, and successful engine relights for landing maneuvers.

Nevertheless, Starship has not yet performed an in-space engine re-ignition for the second stage, a critical component of its diverse mission profiles. It is challenging to ignite a rocket engine in space, as engineers must regulate the temperature of the fuel and the pressure of the tank in the vacuum of space. SpaceX also attributed the uncommon Falcon 9 second-stage engine failure to a liquid oxygen leak during an in-space engine relight.

In addition to re-evaluating the engine performance of the Flight 5 Starship second stage, a static fire should also enable SpaceX to evaluate the new heat shield tiles. These tiles have frequently been observed to detach due to the severe vibrations experienced during starship launches and tests. Engineers should be vigilant for similar incidents during a potential static fire. The installation of the interstage ring should be the booster's next critical area of concern, following its successful static fire, before a potential damp dress rehearsal in preparation for a launch next month.