Soyuz () is a series of spacecraft which has been in service since the 1960s, having made more than 140 flights. It was designed for the Soviet space program by the Korolev Design Bureau (now Energia). The Soyuz succeeded the Voskhod spacecraft and was originally built as part of the Soviet crewed lunar programs. It is launched atop the similarly named Soyuz rocket from the Baikonur Cosmodrome in Kazakhstan.

Following the Soviet Union's dissolution, Roscosmos, the Russian space agency, continued to develop and use the Soyuz. Between the Space Shuttle's 2011 retirement and the SpaceX Crew Dragon's 2020 debut, Soyuz was the sole means of crewed transportation to and from the International Space Station, a role it continues to fulfill. The Soyuz design has also influenced other spacecraft, including China's Shenzhou and Russia's Progress cargo vehicle.

The Soyuz is a single-use spacecraft composed of three main sections. The descent module is where cosmonauts are seated for launch and reentry. The orbital module provides additional living space and storage during orbit but is jettisoned before reentry. The service module, responsible for propulsion and power, is also discarded prior to reentry. For added safety and aerodynamics, the spacecraft is encased within a fairing with a launch escape system during liftoff.

History The first Soyuz mission, Kosmos 133, launched unmanned on 28 November 1966. The first crewed Soyuz mission, Soyuz 1, launched on 23 April 1967 but ended tragically on 24 April 1967 when the parachute failed to deploy on reentry, killing cosmonaut Vladimir Komarov. The following flight, Soyuz 2 was uncrewed. Soyuz 3 launched on 26 October 1968 and became the program's first successful crewed mission. The program suffered another fatal setback during Soyuz 11, where cabin depressurization during reentry killed the entire crew. These are the only humans to date who are known to have died above the Kármán line, the conventional definition of the edge of space.

Despite these early tragedies, Soyuz has earned a reputation as one of the safest and most cost-effective human spaceflight vehicles, a legacy built upon its unparalleled operational history. The spacecraft has served as the primary mode of transport for cosmonauts to and from the Salyut space stations, the Mir space station, and International Space Station (ISS).

Design

Soyuz spacecraft are composed of three primary sections (from top to bottom, when standing on the launch pad):

Orbital module: A spheroid compartment providing living space for the crew. Descent module: A small, aerodynamic capsule where the crew is seated for launch and return the crew to Earth. Service module: A cylindrical section housing propulsion, power, and other systems.

The orbital and service modules are discarded and destroyed upon reentry. This design choice, while seemingly wasteful, reduces the spacecraft's weight by minimizing the amount of heat shielding required. As a result, Soyuz offers more habitable interior space () compared to its Apollo counterpart (). While the reentry module does return to Earth, it is not reusable. A new Soyuz spacecraft is made for each mission.

Soyuz can carry up to three crew members and provide life support for about 30 person-days.

A payload fairing protects Soyuz during launch and is jettisoned early in flight. Equipped with an automated docking system, the spacecraft can operate autonomously or under manual control.

Launch escape system The Vostok spacecraft used an ejector seat to bail out the cosmonaut in the event of a low-altitude launch failure, as well as during reentry; however, it would probably have been ineffective in the first 20 seconds after liftoff, when the altitude would be too low for the parachute to deploy. Inspired by the Mercury LES, Soviet designers began work on a similar system in 1962. This included developing a complex sensing system to monitor various launch-vehicle parameters and trigger an abort if a booster malfunction occurred. Based on data from R-7 launches over the years, engineers developed a list of the most likely failure modes for the vehicle and could narrow down abort conditions to premature separation of a strap-on booster, low engine thrust, loss of combustion-chamber pressure, or loss of booster guidance. The spacecraft abort system (SAS; ) could also be manually activated from the ground, but unlike American spacecraft, there was no way for the cosmonauts to trigger it themselves.

Since it turned out to be almost impossible to separate the entire payload shroud from the Soyuz service module cleanly, the decision was made to have the shroud split between the service module and descent module during an abort. Four folding stabilizers were added to improve aerodynamic stability during ascent. Two test runs of the SAS were carried out in 1966–1967.

The basic design of the SAS has remained almost unchanged in 50 years of use, and all Soyuz launches carry it. The only modification was in 1972, when the aerodynamic fairing over the SAS motor nozzles was removed for weight-saving reasons, as the redesigned Soyuz 7K-T spacecraft carried extra life-support equipment. The uncrewed Progress resupply ferry has a dummy escape tower and removes the stabilizer fins from the payload shroud. There have been three failed launches of a crewed Soyuz vehicle: Soyuz 18a in 1975, Soyuz T-10a in 1983 and Soyuz MS-10 in October 2018. The 1975 failure was aborted after escape-tower jettison. In 1983, Soyuz T-10a's SAS successfully rescued the cosmonauts from an on-pad fire and explosion of the launch vehicle. Most recently, in 2018, the SAS sub-system in the payload shroud of Soyuz MS-10 successfully rescued the cosmonauts from a rocket failure 2 minutes and 45 seconds after liftoff, after the escape tower had already been jettisoned.

Orbital module

The forepart of the spacecraft is the orbital module (), also known as habitation section. It houses all the equipment that will not be needed for reentry, such as experiments, cameras or cargo. The module also contains a toilet, docking avionics and communications gear. Internal volume is , living space is . On later Soyuz versions (since Soyuz TM), a small window was introduced, providing the crew with a forward view.

A hatch between it and the descent module can be closed so as to isolate it to act as an airlock if needed so that crew members could also exit through its side port (near the descent module). On the launch pad, the crew enter the spacecraft through this port. This separation also lets the orbital module be customized to the mission with less risk to the life-critical descent module. The convention of orientation in a micro-g environment differs from that of the descent module, as crew members stand or sit with their heads to the docking port. Also the rescue of the crew whilst on the launch pad or with the SAS system is complicated because of the orbital module.

Separation of the orbital module is critical for a safe landing; without separation of the orbital module, it is not possible for the crew to survive landing in the descent module. This is because the orbital module would interfere with proper deployment of the descent module's parachutes, and the extra mass exceeds the capability of the main parachute and braking engines to provide a safe soft-landing speed. In view of this, the orbital module was separated before the ignition of the return engine until the late 1980s. This guaranteed that the descent module and orbital module would be separated before the descent module was placed in a reentry trajectory. However, after the problematic landing of Soyuz TM-5 in September 1988 this procedure was changed, and the orbital module is now separated after the return maneuver. This change was made as the TM-5 crew could not deorbit for 24 hours after they jettisoned their orbital module, which contained their sanitation facilities and the docking collar needed to attach to Mir. The risk of not being able to separate the orbital module is effectively judged to be less than the risk of needing the facilities in it, including the toilet, following a failed deorbit.

Descent module

The descent module (), also known as a reentry capsule, is used for launch and the journey back to Earth. Half of the descent module is covered by a heat-resistant covering to protect it during reentry; this half faces forward during reentry. It is slowed initially by the atmosphere, then by a braking parachute, followed by the main parachute, which slows the craft for landing. At one meter above the ground, solid-fuel braking engines mounted behind the heat shield are fired to give a soft landing. One of the design requirements for the descent module was for it to have the highest possible volumetric efficiency (internal volume divided by hull area). The best shape for this is a sphere – as the Vostok spacecraft's descent module used – but such a shape can provide no lift, resulting in a purely ballistic reentry. Ballistic reentries are hard on the occupants due to high deceleration and cannot be steered beyond their initial deorbit burn. Thus it was decided to go with the "headlight" shape that the Soyuz uses – a hemispherical upper area joined by a barely angled (seven degrees) conical section to a classic spherical section heat shield. This shape allows a small amount of lift to be generated due to the unequal weight distribution. The nickname was thought up at a time when nearly every headlight was circular. The small dimensions of the descent module led to it having only two-man crews after the death of the Soyuz 11 crew. The later Soyuz-T spacecraft solved this issue. Internal volume of Soyuz SA is ; is usable for crew (living space).

The thermal protection system on the slightly conical side walls is stood off from the structure to also provide micrometeoroid protection in orbit.International Space Station (ISS) Soyuz Vehicle Descent Module Evaluation of Thermal Protection System (TPS) Penetration Characteristics The slightly curved heat shield on the bottom consists of "21mm to 28mm thick ablator (glass-phenolic composite) which is held by brackets approximately 15mm from the 3.5mm thick aluminum AMg-6 substrate. VIM low-density silica fibrous insulation (8mm thick) is contained in the gap between the heat shield ablator and aluminum substrate."

Service module

At the back of the vehicle is the service module (). It has a pressurized container shaped like a bulging can (instrumentation compartment, ) that contains systems for temperature control, electric power supply, long-range radio communications, radio telemetry, and instruments for orientation and control. A non-pressurized part of the service module (propulsion compartment, ) contains the main engine and a liquid-fuelled propulsion system, using N2O4 and UDMH, for maneuvering in orbit and initiating the descent back to Earth. The ship also has a system of low-thrust engines for orientation, attached to the intermediate compartment (). Outside the service module are the sensors for the orientation system and the solar array, which is oriented towards the Sun by rotating the ship. An incomplete separation between the service and reentry modules led to emergency situations during Soyuz 5, Soyuz TMA-10 and Soyuz TMA-11, which led to an incorrect reentry orientation (crew ingress hatch first). The failure of several explosive bolts did not cut the connection between the service and reentry modules on the later two flights.

Reentry procedure