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Foam Problems

  • In the Early Days of the Space Shuttle , The Foam never seemed to be a problem? Why has it been such a problem since Columbia's demise ? Mongolia


  • Hello again, Mongolia! Foam shedding had been observed on previous shuttle flights. Since the earlier incidents had no serious consequences, the dangerous significance of such incidents was discounted, much as the known problems with O-rings had been shrugged off before the Challenger disaster. "Foam ejection during launch has been a problem with quite a long history. Four previous shuttle launches had foam falling from the bipod area: Challenger in 1983, Columbia in 1990 and 1992, and Atlantis last October. Engineers had made many changes in the foam design in the past few years, but the problem had not been solved." http://www.csa.com/discoveryguides/shuttle/overview.php "From the day of Columbia's breakup forward, shuttle program manager Ron Dittemore has defended the NASA analysis finding that the foam impact could not possibly have caused enough damage to trigger Columbia's destruction 16 days after launch. Dittemore cited as evidence previous incidents involving foam from the external tank. During a number of flights in recent years, the external tank insulation beneath the orbiter 'popcorned' during ascent because of escaping gas beneath the sprayed-on foam, creating dings in hundreds of tiles. The damage was never severe enough to notice during descent. Just in October, a larger chunk of foam came free from the external tank and caused only minor damage to one of Atlantis' solid-fuel booster rockets. The logic, though, appears to mirror that used by NASA 17 years earlier, when it discounted the significance of partial burn-through of rubbery booster-rocket O-rings it had seen in previous flights." http://www.palmbeachpost.com/news/content/news/shuttle/0209columbia.html "Before the shuttle mission preceding Columbia's fateful flight, NASA flagged as a major concern a loss of foam in the same area on fuel tanks where investigators now believe debris broke away and smashed against Columbia's left wing. The space agency concluded that damage from such breakaway foam did not threaten shuttle safety and determined the fuel tank attached to Endeavour was "safe to fly with no new concerns and no added risk," according to newly released documents from the National Aeronautics and Space Administration. The documents revealed for the first time some of NASA's reasons for deciding months ago that such risks were insufficient to delay shuttle launches, even as agency officials already were looking into what they perceived as a frustrating, recurring problem." http://www.cbsnews.com/stories/2003/03/21/columbia/main545149.shtml I'll be glad to gather additional material of a similar nature, if that would constitute a fully satisfactory answer.


  • Hi Pink Please go ahead and post. Mongolia


  • Thank you for accepting my findings as your official answer. I've reposted the material below, with an additional NASA link that I hope will be of interest. Foam shedding had been observed on previous shuttle flights. Since the earlier incidents had no serious consequences, the dangerous significance of such incidents was discounted, much as the known problems with O-rings had been shrugged off before the Challenger disaster. "Foam ejection during launch has been a problem with quite a long history. Four previous shuttle launches had foam falling from the bipod area: Challenger in 1983, Columbia in 1990 and 1992, and Atlantis last October. Engineers had made many changes in the foam design in the past few years, but the problem had not been solved." CSA: Columbia Shuttle Tragedy http://www.csa.com/discoveryguides/shuttle/overview.php "From the day of Columbia's breakup forward, shuttle program manager Ron Dittemore has defended the NASA analysis finding that the foam impact could not possibly have caused enough damage to trigger Columbia's destruction 16 days after launch. Dittemore cited as evidence previous incidents involving foam from the external tank. During a number of flights in recent years, the external tank insulation beneath the orbiter 'popcorned' during ascent because of escaping gas beneath the sprayed-on foam, creating dings in hundreds of tiles. The damage was never severe enough to notice during descent. Just in October, a larger chunk of foam came free from the external tank and caused only minor damage to one of Atlantis' solid-fuel booster rockets. The logic, though, appears to mirror that used by NASA 17 years earlier, when it discounted the significance of partial burn-through of rubbery booster-rocket O-rings it had seen in previous flights." Palm Beach Post: NASA mind-set yields comparison, clues http://www.palmbeachpost.com/news/content/news/shuttle/0209columbia.html "Before the shuttle mission preceding Columbia's fateful flight, NASA flagged as a major concern a loss of foam in the same area on fuel tanks where investigators now believe debris broke away and smashed against Columbia's left wing. The space agency concluded that damage from such breakaway foam did not threaten shuttle safety and determined the fuel tank attached to Endeavour was 'safe to fly with no new concerns and no added risk,' according to newly released documents from the National Aeronautics and Space Administration. The documents revealed for the first time some of NASA's reasons for deciding months ago that such risks were insufficient to delay shuttle launches, even as agency officials already were looking into what they perceived as a frustrating, recurring problem." CBS News: Shuttle Foam Had History Of Problems http://www.cbsnews.com/stories/2003/03/21/columbia/main545149.shtml "What Are the 'Echoes' of Challenger? Former shuttle astronaut Sally Ride served on the Rogers Commission that investigated the January 1986 Challenger accident, which claimed the lives of seven astronauts, and on CAIB. During the Columbia investigation, she said she heard 'echoes' of Challenger as it became clear that the accident resulted from NASA failing to recognize that a technical failure (bipod ramp foam shedding) that had occurred on previous shuttle flights could have safety-of-flight implications even if the earlier missions were completed successfully. In the case of CRS-4 Challenger, it was erosion of seals (O-rings) between segments of the Solid Rocket Booster, which had been noted on previous missions. Some engineers warned NASA not to launch Challenger that day because unusually cold weather could have weakened the resiliency of the O-rings. They were overruled. CAIB concluded that 'both accidents were failures of foresight' - and the parallels between them demonstrate that: 'the causes of the institutional failure responsible for Challenger have not been fixed; if these persistent, systemic flaws are not resolved, the scene is set for another accident'; and that while individuals must be accountable for their actions, 'NASA?s problems cannot be solved simply by retirements, resignations, or transferring personnel'." NASA History Division: NASA?s Space Shuttle Columbia: Synopsis of the Report of the Columbia Accident Investigation Board http://history.nasa.gov/columbia/Troxell/Columbia%20Web%20Site/Documents/Congress/CRS%20Summary%20of%20CAIB%20Report.pdf My Google search strategy: Google Web Search: shuttle columbia foam previous ://www.google.com/search?hl=en&q=shuttle+columbia+foam+previous Very best regards, Pink







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