NASA uncovers a 19-year fraud that caused failed missions

An investigation finds the cause of failed NASA launches and $700 million in losses.

NASA's Orbiting Carbon Observatory on the launch pad at Vandenberg Air Force Base in California. Image credit: NASA/Randy Beaudoin
  • An Oregon company provided falsified tests to a NASA rocket builder for almost two decades.
  • The company is now liable for $46 million in payments and the lab manager went to prison.
  • NASA can't test every single component itself, making it important the supply chain is protected.

An Oregon aluminum manufacturer has been defrauding NASA for almost twenty years, resulting in failed missions, announced the Department of Justice.

Sapa Profiles Inc. (SPI), now known as Hydro Extrusion Portland Inc., carried out a 19-year scam that included falsifying thousands of critical test documents, leading to the failed 2009 and 2011 launches of NASA's Orbiting Carbon Observatory and Glory missions.

NASA Launch Services Program's multi-year investigation revealed that the malfunctions were caused by faulty aluminum. The launch vehicle "fairings" – specialized clamshell structures covering the mission satellites aboard the Taurus XL rocket – failed to separate due to the deficiency of the metal, provided by SPI.

The company's employees routinely changed inconvenient numbers and violated test standards and specifications, doctoring the speeds of machines used in the testing and utilizing incorrect sample sizes. The wrong information about aluminum extrusions was then employed in the payload fairing rail "frangible joints" by Orbital Sciences Corporation, the rocket's manufacturer.

An artist's concept of the Orbiting Carbon Observatory, which was supposed to study atmospheric carbon dioxide.

Image credit: NASA/JPL

The company went as far as using other clients, some being contracted by the government, to provide misleading certifications.

SPI (Hydro Extrusion Portland) is now liable for $46 million in payments, a small price to pay if you consider the $700 million cost of the failed missions attributed to these aluminum defects. Jim Norman, director for Launch Services at NASA Headquarters in Washington, weighed in on the seriousness of the fraud, saying that NASA just can't possibly test every single component and if suppliers are dishonest, missions could fail.

"In our case, the Taurus XLs that failed for the OCO and Glory missions resulted in the loss of more than $700 million, and years of people's scientific work, " explained Norman. "It is critical that we are able to trust our industry to produce, test and certify materials in accordance with the standards we require. In this case, our trust was severely violated."

U.S. Attorney G. Zachary Terwilliger for the Eastern District of Virginia, commenting for the DOJ, did not mince words either:

"For nearly two decades, SPI and its employees covered up substandard manufacturing processes by brazenly falsifying test results," said Terwilliger. "They then provided the false test results to hundreds of customers across the country, all to increase corporate profits and obtain production-based bonuses."

All criminal charges and civil claims against Sapa Profiles Inc. are being resolved with this arrangement. The testing lab supervisor, Dennis Balius, got three years of jail time for his role. The company has been suspended from doing business with the U.S. government since 2015.

Yug, age 7, and Alia, age 10, both entered Let Grow's "Independence Challenge" essay contest.

Photos: Courtesy of Let Grow
Sponsored by Charles Koch Foundation
  • The coronavirus pandemic may have a silver lining: It shows how insanely resourceful kids really are.
  • Let Grow, a non-profit promoting independence as a critical part of childhood, ran an "Independence Challenge" essay contest for kids. Here are a few of the amazing essays that came in.
  • Download Let Grow's free Independence Kit with ideas for kids.
Keep reading Show less

Four philosophers who realized they were completely wrong about things

Philosophers like to present their works as if everything before it was wrong. Sometimes, they even say they have ended the need for more philosophy. So, what happens when somebody realizes they were mistaken?

Sartre and Wittgenstein realize they were mistaken. (Getty Images)
Culture & Religion

Sometimes philosophers are wrong and admitting that you could be wrong is a big part of being a real philosopher. While most philosophers make minor adjustments to their arguments to correct for mistakes, others make large shifts in their thinking. Here, we have four philosophers who went back on what they said earlier in often radical ways. 

Keep reading Show less

Is there a limit to optimism when it comes to climate change?

Or is doubt a self-fulfilling prophecy?

David McNew/Getty Images
Politics & Current Affairs

'We're doomed': a common refrain in casual conversation about climate change.

Keep reading Show less

What should schools teach? Now is the moment to ask.

The future of learning will be different, and now is the time to lay the groundwork.

What should schools teach? Now is the moment to ask. | Caroline ...
Future of Learning
  • The coronavirus pandemic has left many at an interesting crossroads in terms of mapping out the future of their respective fields and industries. For schools, that may mean a total shift not only in how educators teach, but what they teach.
  • One important strategy moving forward, thought leader Caroline Hill says, is to push back against the idea that getting ahead is more important than getting along. "The opportunity that education has in this moment to really push students and think about what is the right way to live, how do we do it and how do we do it in a way that doesn't hurt or rob the dignity of other people?"
  • Hill also argues that now is the time for bigger swings and for removing the barriers that limit education. The online space is boundary free and provides educators with new opportunities to connect with students around the world.

Keep reading Show less
Scroll down to load more…