First was the discovery that it lacked sufficient power to lift astronauts in a state-of-the-art capsule into orbit. Then engineers found out that it might vibrate like a giant tuning fork, shaking its crew to death.
Now, in the latest setback to the Ares I, computer models show the ship could crash into its launch tower during liftoff.
Now several engineers are speaking out, saying Ares should be canceled because it's expensive and potentially dangerous.
"It's time for a rethink," said Jeff Finckenor, an award-winning NASA engineer who last month quit the Ares program in frustration over the way the program is being managed.
The Sentinel reviewed more than 800 pages of NASA documents and internal studies and interviewed more than a dozen engineers, technicians and NASA officials involved with the project. Most, fearing retribution from NASA management, spoke on condition that their names would not be used.
All agreed that, eventually, NASA would be able to get Ares I to fly. The real question, they said, is whether the agency will be able to build it on time and on budget. What's more, they said, it will never be the robust, simple rocket that NASA intended.
"If they push hard enough, yes, it will fly," said one NASA engineer working on Ares. "But there are going to be so many compromises to be able to launch it, and it will be so expensive and so behind schedule, that it may be better if didn't fly at all."
NASA had to quell near-revolts by astronauts and scientists who last month took issue during a preliminary design review of Ares I. In the end, they were cajoled into backing the review.
The review graded the rocket against 10 criteria from NASA's program-management handbook. Seven of the marks were the equivalent of a C or a D. Overall, the project earned a grade-point average of 2.1, a low C.
The reasons for the low grades included concerns that its electronics and control systems could be shaken apart on liftoff and the launch-drift issue.
Astronauts, whose prime concern is safety, are still not happy.
Leroy Chiao, a former space-station commander who retired in 2005, stays in touch with his colleagues.
"I would say that I have heard various concerns," he said. "If I were still in the corps, I'd be skeptical about when is this thing going to fly and will we be able to put all the fixes in place."
One reason the astronauts are angry, Chiao and others say, is because NASA earlier this year relaxed its own safety requirements when it realized that Ares I could not meet rigid rules demanding triple redundancy on all critical systems.
The extra systems added too much weight. So, engineers said, NASA rewrote the rules to allow managers to decide how many backup systems each component needed.
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