Princeton Professor Adam Burrows asks Elon Musk why SpaceX rocket engines are built with stainless steel instead of carbon fiber. As Elon Musk walks him through the decision, it becomes clear why he chose steel, especially when one considers that safe re-entry and re-usability are primary goals. Below is a nine-minute video from Twitter/X:
If you want a detailed explanation of why I switched Starship from carbon fiber to stainless steel
— Elon Musk (@elonmusk) June 7, 2024
pic.twitter.com/pXC0ngheiw
Perhaps as important as his technical knowledge, experimentation and even acceptance of failure (within reason) are key components of Elon Musk's success.
Elon Musk thought at the outset that SpaceX would probably use carbon fiber. As it tested carbon fiber, stainless steel, and aluminum, it found that steel's strength increased at the extremely cold temperatures (-297.3°F / -182.96°C) necessary to contain the liquid oxygen in the fuel mix. Lining a carbon-fiber engine to secure it against cold is complicated compared to steel, and even if that problem is solved, carbon-fiber would only be as strong as stainless steel.
Steel also held up better than fiber and aluminum at high re-entry temperatures and required a thinner (lower weight) heat shield. The fact that stainless steel is much easier to work with and is much cheaper than other materials are added bonuses.
In most large organizations everyone is afraid of making a mistake that could cost them their jobs. His willingness to fail--and thereby learn--and his power to call the shots are why Elon Musk's companies are far ahead of their competition.
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