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Fischbeck
Study Focused on Space Shuttle Tiles
A
technical report coauthored by Prof. Elisabeth Pate-Cornell
at Stanford and Prof. Paul Fischbeck (SDS/EPP) more than
a decade ago warned that the space shuttle could be destroyed
if heat tiles protecting critical wing parts were damaged
by debris. The examination of roughly 30 early shuttle
flights identified segments of the 20,000-plus protective
tiles that were most prone to fail and cause a catastrophic
event. Just 15 percent of the tiles were found to account
for about 85 percent of the risk of a burn-through that
would destroy the orbiter.
The report included
a recommendation that NASA take steps to prevent foam
chunks from falling off the external tank and striking
those risk critical tiles that were more sensitive
to debris strikes and weakened bonding and that protected
some of the subsystems most critical to the ships
safe landing.
NASA struggled
for years trying to ensure that the tiles were firmly
attached to the shuttle, said Fischbeck. They
took a lot of our advice to heart and made changes to
lower the risk of debris hitting the tiles during launch.
But the problems were never completely resolved.
Pate-Cornell and Fischbeck
made an initial report to NASA on their findings in 1990,
and they later published follow-up papers on the research
in 1993-1994. Fischbeck said that they studied debris
strikes during the first 50 shuttle launches and concluded
that on average about 25 thermal tiles per flight
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sustained damage of at least one inch. The analysis found
that the most vulnerable parts of the shuttle were the
undersides of the wings close to the fuselage and right
under the crew compartment.
NASA experts have
reported that data from the Columbia shows a sudden temperature
risea marker for failed tilesin the left wheel
well, an area Fischbecks and Pate-Cornells
report said was a critical risk. The report also said
that NASA needed to devote additional attention to training
technicians to glue tiles on the hull of the space shuttle
and then test the strength of the bonding. An adhesive
used for the tiles hardened more quickly if it was wet,
and the report said NASA found one technician helping
the process along by spitting into the glue. Unfortunately,
wetting the glue compromised the bond. To detect weak
bonds, experienced technicians acheck each tile with a
wiggle test, the report said.
Fischbeck says NASA
has made improvements in protecting and maintaining the
tile system since their early study. Insulation on the
solid rocket boosters has been changed, and there are
stricter limits on the amount of ice allowed on the external
fuel tank before a launch. However, recent changes in
the design of the external tank have led to increased
tile damage.
After the recent Columbia
accident, this work has generated interest at a variety
of news outlets including: NBC, ABC, CBS, CNN, Fox News,
The New York Times, The Washington Post, The Houston Chronicle,
The Wall Street Journal, NPR and a litany other national
and trade publications.
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| Department
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