By demanding strict safety procedures for the Axiom-4 mission, the Indian Space Research Organization (ISRO) was instrumental in averting what might have been a devastating space catastrophe. A serious catastrophe that might have claimed lives was prevented by the prompt discovery of a critical crack in the oxidizer line of SpaceX’s Falcon-9 rocket, which was scheduled to transport four astronauts, including India’s Group Captain Shubhanshu Shukla, to the International Space Station.
ISRO Chairman Dr. V Narayanan, whose knowledge of cryogenic propulsion systems was crucial in determining the extent of the problem, demanded thorough due diligence, which led to the discovery of the fault. In order to confirm the Falcon-9’s booster stage’s functionality, a seven-second hot test was performed on the launch pad.
Dr. Narayanan, a renowned rocket propulsion specialist who was instrumental in the development of India’s cryogenic engine technology, recognized the dangers of the liquid oxygen leak right away. He was uniquely qualified to evaluate the risks due to his technical background, which included leading ISRO’s cryogenic propulsion program and earning an M.Tech in Cryogenic Engineering from IIT-Kharagpur. Dr. Narayanan was adamantly opposed to moving forward with the launch when SpaceX Vice President William Gerstenmaier acknowledged the leak during a mission readiness review, initially downplaying its importance.
Before any launch clearance could be given, the ISRO chief insisted that the leak be completely fixed and validated by appropriate testing, including low-temperature leak tests. SpaceX’s “band-aid-like” solution of installing a purge system to mitigate the leak did not convince a highly qualified 13-member ISRO team stationed at Kennedy Space Center in Florida, which supported this insistence on strict safety protocols.
Despite admitting the propellant leak, SpaceX had originally intended to launch on June 11, 2025. SpaceX would be “fully ready to go fly” and “essentially mitigate the leak if it continues” with a purge system, according to Gerstenmaier. However, SpaceX teams were compelled to return to the launch pad for more in-depth inspections due to ISRO’s strict stance.
A large weld crack in one of the liquid oxygen lines was discovered as a result of these extra inspections, which had previously gone undetected. Given that the first stage was a reconditioned and recycled booster that had been utilized in an earlier Starlink mission, this structural defect was especially worrisome. It was acknowledged that SpaceX had “not fully repaired the booster during refurbishment, or we didn’t find the leak and didn’t get it corrected” during the previous flight.
In this case, Dr. Narayanan’s experience was invaluable because he had played a key role in India’s historic space missions, including chairing the National Level Expert Committee that determined the root causes of Chandrayaan-2’s problems and spearheading the development of crucial phases for the Chandrayaan missions. He recognized the significant risks posed by the liquid oxygen leak because of his extensive knowledge of liquid propulsion systems, which he acquired over decades of working on India’s cryogenic engine development during international technology denial regimes.
Because liquid oxygen is extremely reactive and can start fires, experts who evaluated the safety situation confirmed that the rocket might have experienced a serious failure during liftoff if the crack had gone undetected. The already compromised weld might have completely fractured due to the enormous vibrations that happen during rocket liftoff, which could have resulted in catastrophic failure.
Other foreign partners endorsed ISRO’s safety-first strategy; according to sources, the Polish and Hungarian teams supported the Indian delegation’s position. ISRO’s “Safety-first, Launch-later” strategy reportedly relieved Axiom Space’s leadership, and many at Cape Canaveral praised the Indian space agency’s handling of the matter.
For India, which had spent about ₹550 crores (roughly $65 million) to guarantee Group Captain Shubhanshu Shukla a spot on the Axiom-4 mission, the stakes were especially high. Shukla will be the first Indian astronaut to visit the International Space Station on this mission, marking India’s return to human spaceflight after 41 years. In addition, mission specialists Slawosz Uzananski-Wisniewski from Poland and Tibor Kapu from Hungary are part of the mission crew, along with Commander Peggy Whitson from the United States.
The damaged section of the oxidizer line was fully replaced after ISRO insisted, and sufficient validation testing was carried out to guarantee the integrity of the restored system. ISRO issued a statement stating that “During a follow-on coordination meeting between ISRO, Axiom Space, and SpaceX, it was confirmed that the liquid oxygen leak observed in the Falcon 9 launch vehicle has been successfully resolved” .
“We appreciate all the incredible work of our customers, NASA, and SpaceX on this Mission,” said Kam Ghaffarian, Executive Chairman of Axiom Space, in acknowledgment of ISRO’s contribution to mission safety. For the benefit of Axiom Space, NASA, and our clients, this is the proper course of action. This was a tacit acknowledgement of ISRO’s pivotal role in averting a possible catastrophe.
According to the most recent reports, NASA has stated that it is evaluating launch opportunities through June 30, 2025, with the launch window remaining open until June 19 at the latest. By completely filling the Falcon-9 with liquid propellants and simulating a launch countdown without actually starting the engines, SpaceX has finished a wet dress rehearsal. Group Captain Shukla and the other four members of the crew are still in quarantine while they await the official launch date.
In addition to the rocket repairs, NASA and Axiom Space are evaluating a different pressure anomaly in the International Space Station’s Zvezda Service Module, which presents additional challenges for the mission. Intermittent pressure problems have plagued this Russian portion of the ISS, making mission planning even more difficult.
This incident is a stark reminder that, despite schedule constraints and financial considerations, safety procedures cannot be compromised in human spaceflight. It’s possible that ISRO’s steadfast dedication to careful verification and appropriate repairs saved the lives of four astronauts and avoided a disaster that might have had a major effect on the future of commercial human spaceflight.
