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The Reconstruction and Failure Analysis of The Space Shuttle Columbia

This viewgraph presentation describes a very detailed reconstruction plan and failure analysis of The Space Shuttle Columbia accident. The contents include: 1) STS-107 Timeline; 2) Foam Impact; 3) Recovery; 4) Reconstruction; 5) Reconstruction Plan; 6) Reconstruction Hanger; 7) Pathfinders; 8) Aluminum Pathfinder; 9) Early Analysis - Left MLG Door Area; 10) Emphasis Switched to Left Hand Wing Leading Edge; 11) Wing Leading Edge Subsystem (LESS); 12) 3D Reconstruction of Left WLE; 13) Left Wing Tile Table; 14) LESS Observations; 15) Left Hand Wing Debris Points to RCC 8/9 - Slumped Tile; 16) Reconstructed View of LC/P 9 tile with I/B Tile; 17) Reconstructed View of Lower C/P 9 Tile; 18) Carrier Panel 8 - Upper; 19) Left Hand Wing Debris Points to RCC 8/9 - Erosion and RCC with attach hole intact; 20) Erosion on Panel 8 Upper Outboard Rib; 21) RCC Panels 8 & 9 Erosion Features; 22) Slumping Source for Carrier Panel 9 Tile was Revealed; 23) Debris Indicated Highest Probability Initiation Site; 24) Left Hand Wing Debris Points to RCC 8/9- Metallic Deposits; 25) Relative Metallic Deposition on L/H Wing Materials; 26) Metallic Deposit Example, LH RCC 8; 27) High Level Questions; 28) Analysis Plan Challenges; 29) Analysis Techniques; 30) Analysis Approach; 31) RCC Panel 8 Erosion Features; 32) Radiographic Features; 33) Radiography WLE LH Panel 8; 34) LH RCC 8 Upper Apex; 35) LH RCC 8 - Deposit Feature: Thick Tear Shaped; 36) LH RCC 8 - Deposit Feature: Thick Globules; 37) LH RCC 8 - Deposit Feature: Spheroids; 38) LH RCC 8 - Deposit Feature: Uniform Deposit; 39) Significant Findings - Sampling All Other panels; 40) Proposed Breach Location and Plasma Flow; 41) Corroborating Information - RCC Panel Debris Locations; 42) Corroborating Information - LH OMS Pod Analysis; 43) Corroborating Information - Impact Testing; and 44) Overall Forensic Conclusions.

Russell, Richard W.↗

Application of Electron Microscopy Techniques to the Investigation of Space Shuttle Columbia Accident

This viewgraph presentation gives an overview of the investigation into the breakup of the Space Shuttle Columbia, and addresses the importance of a failure analysis strategy for the investigation of the Columbia accident. The main focus of the presentation is on the usefulness of electron microscopy for analyzing slag deposits from the tiles and reinforced carbon-carbon (RCC) wing panels of the Columbia orbiter.

Shah, Sandeep↗

A Summary of the Space Shuttle Columbia Tragedy and the Use of LS Dyna in the Accident Investigation and Return to Flight Efforts

On February 1, 2003, the Space Shuttle Columbia broke apart during reentry resulting in loss of 7 crewmembers and craft. For the next several months an extensive investigation of the accident ensued involving a nationwide team of experts from NASA, industry, and academia, spanning dozens of technical disciplines. The Columbia Accident Investigation Board (CAIB), a group of experts assembled to conduct an investigation independent of NASA concluded in August, 2003 that the cause of the loss of Columbia and its crew was a breach in the left wing leading edge Reinforced Carbon-Carbon (RCC) thermal protection system initiated by the impact of thermal insulating foam that had separated from the orbiters external fuel tank 81 seconds into the missions launch. During reentry, this breach allowed superheated air to penetrate behind the leading edge and erode the aluminum structure of left wing which ultimately led to the breakup of the orbiter. In order to gain a better understanding the foam impact on the orbiters RCC wing leading edge, a multi-center team of NASA and Boeing impact experts was formed to characterize the foam and RCC materials for impact analysis using LS Dyna. Dyna predictions were validated with sub-component and full scale tests. LS Dyna proved to be a valuable asset in supporting both the Columbia Accident Investigation and NASA s return to flight efforts. This paper summarizes Columbia Accident and the nearly seven month long investigation that followed. The use of LS-DYNA in this effort is highlighted. Contributions to the investigation and return to flight efforts of the multicenter team consisting of members from NASA Glenn, NASA Langley, and Boeing Philadelphia are introduced and covered in detail in papers to follow in these proceedings.

Melis, Matthew↗

The microgravity environment of the Space Shuttle Columbia payload bay during STS-32

Over 11 hours of three-axis microgravity accelerometer data were successfully measured in the payload bay of Space Shuttle Columbia as part of the Microgravity Disturbances Experiment on STS-32. These data were measured using the High Resolution Accelerometer Package and the Aerodynamic Coefficient Identification Package which were mounted on the Orbiter keel in the aft payload bay. Data were recorded during specific mission events such as Orbiter quiescent periods, crew exercise on the treadmill, and numerous Orbiter engine burns. Orbiter background levels were measured in the 10(exp -5) G range, treadmill operations in the 10(exp -3) G range, and the Orbiter engine burns in the 10(exp -2) G range. Induced acceleration levels resulting from the SYNCOM satellite deploy were in the 10 (exp -2) G range, and operations during the pre-entry Flight Control System checkout were in the 10(exp -2) to 10(exp -1) G range.

Dunbar, Bonnie J.↗

The Space Shuttle Columbia Preservation Project - The Debris Loan Process

The purpose of this project is to provide a process for loan of Columbia debris to qualified researchers and technical educators to: (1) Aid in advanced spacecraft design and flight safety development (2) Advance the study of hypersonic re-entry to enhance ground safety. (3) Train and instruct accident investigators and (4) Establish an enduring legacy for Space Shuttle Columbia and her crew.

Thurston, Scott↗

Summary of longitudinal stability and control parameters as determined from space shuttle Columbia flight test data

Extensive wind tunnel tests were conducted to establish the preflight aerodynamics of the Shuttle vehicle. This paper presents the longitudinal, short-period aerodynamics of the space shuttle Columbia as determined from flight test data. These flight-determined results are compared with the preflight predictions, and areas of agreement or disagreement are noted. In addition to the short-period aerodynamics, the pitch RCS effectiveness was determined.

Suit, W. T.↗

Lightning flash mensuration using video from the Space Shuttle Columbia (STS-32)

Using the payload bay television cameras from various Space Shuttle missions, a study was performed to investigate the relationship between the size and duration of lightning flashes, though separated by 1-100 km, that appeared to be flashing in synchronization. The area, duration, and rate of propagation of the lightning in these storms was also studied. By employing the analytical methods described, the use of deinterlaced video of lightning observed from STS-32 provides the highest sampling rate ever utilized for this purpose from space (1 image each 16.7 m/sec).

Pitts, David E.↗

Lateral stability and control derivatives extracted from five early flights of the space shuttle Columbia

Flight data taken from the first five flights (STS-2, 3, 4, 5 and 9) of the Space Transportation System Shuttle Columbia during entry are analyzed to determine the Shuttle lateral aerodynamic characteristics. Maximum likelihood estimation is applied to data derived from accelerometer and rate gyro measurements and trajectory, meteorological and control surface data to estimate lateral-directional stability and control derivatives. The estimated parameters are compared across the five flights and to preflight predicted values.

Schiess, J. R.↗

Space Shuttle Columbia Reconstruction Effort: An Analysis of the Thermal Protection System.

Upon the breakup of the Space Shuffle Columbia, which occurred during peak heating, at an altitude of 200,000 feet, and traveling at Mach 19, the daunting responsibility was placed upon National Aeronautics and Space Administration (NASA) to determine the root cause of the accident. One of the foremost tasks was to begin locating Columbia's debris, which was scattered acr ss a 2,000 square miles area of Texas and into western Louisiana. Each potential shuttle debris piece found was categorized and the longitude and latitude noted. This provided crucial data to the vehicle's breakup trajectory path and aided in locating key shuffle components. Since the airframe and tiles would be the primary focus during the reconstruction effort at the Kennedy Space center in Florida, packing and shipping was crucial to the preservation of the shape and condition of each recovered object. Over 83,000 pieces of Columbia, in a five-month timeframe, were located. The recovered tiles still bonded to structure indicated failures modes due to heating and aerodynamic loads. Also, different types of tile bond failure modes were observed, with adhesion failures at the Koropon layer or material failure at the tile's densification layer. Numerous tiles had the identification markings burned off, slumping of the Reaction-Cured Glass (RCG) coating, and of the Ll-900 silica base material. The conditions in which the tiles were found resulted in developing methods to aid in the identification of the tile. Correctly identifying each tile was critical to understanding the heating patterns of the tiles in relationship to the vehicle, since it was known that the lower left wing received the initial external tank foam impact. With the aid of multiple disciplines, the clues found in the TPS debris, lead to the root cause of the breakup of Columbia.

Micklos, Ann M.↗

Loss of Signal, Aeromedical Lessons Learned from the STS-107 Columbia Space Shuttle Mishap

Loss of Signal, a NASA publication to be available in May 2014 presents the aeromedical lessons learned from the Columbia accident that will enhance crew safety and survival on human space flight missions. These lessons were presented to limited audiences at three separate Aerospace Medical Association (AsMA) conferences: in 2004 in Anchorage, Alaska, on the causes of the accident; in 2005 in Kansas City, Missouri, on the response, recovery, and identification aspects of the investigation; and in 2011, again in Anchorage, Alaska, on future implications for human space flight. As we embark on the development of new spacefaring vehicles through both government and commercial efforts, the NASA Johnson Space Center Human Health and Performance Directorate is continuing to make this information available to a wider audience engaged in the design and development of future space vehicles. Loss of Signal summarizes and consolidates the aeromedical impacts of the Columbia mishap process-the response, recovery, identification, investigative studies, medical and legal forensic analysis, and future preparation that are needed to respond to spacecraft mishaps. The goal of this book is to provide an account of the aeromedical aspects of the Columbia accident and the investigation that followed, and to encourage aerospace medical specialists to continue to capture information, learn from it, and improve procedures and spacecraft designs for the safety of future crews. This poster presents an outline of Loss of Signal contents and highlights from each of five sections - the mission and mishap, the response, the investigation, the analysis and the future.

Stepaniak, Phillip C.↗

Loss of Signal, Aeromedical Lessons Learned for the STS-I07 Columbia Space Shuttle Mishap

Loss of Signal, a NASA publication to be available in May 2014, presents the aeromedical lessons learned from the Columbia accident that will enhance crew safety and survival on human space flight missions. These lessons were presented to limited audiences at three separate Aerospace Medical Association (AsMA) conferences: in 2004 in Anchorage, Alaska, on the causes of the accident; in 2005 in Kansas City, Missouri, on the response, recovery, and identification aspects of the investigation; and in 2011, again in Anchorage, Alaska, on future implications for human space flight. As we embark on the development of new spacefaring vehicles through both government and commercial efforts, the NASA Johnson Space Center Human Health and Performance Directorate is continuing to make this information available to a wider audience engaged in the design and development of future space vehicles. Loss of Signal summarizes and consolidates the aeromedical impacts of the Columbia mishap process-the response, recovery, identification, investigative studies, medical and legal forensic analysis, and future preparation that are needed to respond to spacecraft mishaps. The goals of this book are to provide an account of the aeromedical aspects of the Columbia accident and the investigation that followed, and to encourage aerospace medical specialists to continue to capture information, learn from it, and improve procedures and spacecraft designs for the safety of future crews.

Patlach, Robert↗

The Reconstruction and Failure Analysis of the Space Shuttle Columbia

Several days following the Columbia accident a team formed and began planning for the reconstruction of Columbia. A hangar at the Kennedy Space Center was selected for this effort due to it's size, available technical workforce and materials science laboratories and access to the vehicle ground processing infrastructure. The Reconstruction team established processes for receiving, handling, decontamination, tracking, identifying, cleaning and assessment of the debris. Initially, a 2-dimensional reconstruction of the Orbiter outer mold line was developed. As the investigation progressed fixtures which allowed a 3-dimensional reconstruction of the forward portions of the left wing's leading edge was developed. To support the reconstructions and forensic analyses a Materials and Processes (M&P) 'team was formed. This M&P team established processes for recording factual observations, debris cleaning, and engineering analysis. Fracture surfaces and thermal effects of selected airframe debris were assessed, and process flows for both nondestructive and destructive sampling and evaluation of debris were developed. The Team also assessed left hand airframe components that were believed to be associated with a structural breach of Columbia. A major portion of this analysis was evaluation of metallic deposits were prevalent on left wing leading edge components. Extensive evaluation of the visual, metallurgical and chemical nature of the deposits provided conclusions that were consistent with the visual assessments and interpretations of the NASA lead teams and the findings of the Columbia Accident Investigation Board. Analytical data collected by the M&P Team showed that a significant thermal event occurred at the left wing leading edge in the proximity of LH RCC Panels 8-9, and a correlation was formed between the deposits and overheating in these areas to the wing leading edge components. The analysis of deposits also showed exposure to temperatures in excess of 1649 C (3200 F), which would severely degrade support structure, tiles, and RCC panel materials. The integrated failure analysis of wing leading edge debris and deposits strongly supported the hypothesis that a breach occurred at LH RCC Panel 8.

Russell, Richard↗

The microgravity environment of the Space Shuttle Columbia middeck during STS-32

Four hours of three-axis microgravity accelerometer data were successfully measured at the MA9F locker location in the Orbiter middeck of Columbia as part of the Microgravity Disturbances Experiment (MDE) on STS-32. These data were measured using the Honeywell In-Space Accelerometer, a small three-axis accelerometer that was hard-mounted onto the Fluid Experiment Apparatus to record the microgravity environment at the exact location of the MDE. Data were recorded during specific mission events such as Orbiter quiescent periods, crew exercise on the treadmill, and numerous Orbiter engine burns. Orbiter background levels were measured to be in the 3 x 10(exp -5) to 2 x 10(exp -4) G range, treadmill operations in the 6 x 10(exp -4) to 5 x 10(exp -3) G range, and Orbiter engine burns from 4 x 10(exp -3) to in excess of 1 x 10(exp -2) G. These data represent some of the first microgravity accelerometer data ever recorded in the middeck area of the Orbiter.

Dunbar, Bonnie J.↗

Post flight operation of a high peak power neodymium YAG laser aboard the G-449 payload flown on Space Shuttle Columbia mission 61-C

The Nd Yag laser flown on board the G-449 payload completed its postflight testing successfully. There was no indication that the laser had undergone any electronic or optical component failure. A postflight video was taken immediately following the return of the payload to the laboratory. Early anticipation of vibration and temperature changes contributed to the successful operation of the laser. Photographic material resulting from post flight videotape are presented. NASA safety reviews and recommendations supplied the insights which helped contribute to the successful operation of the Nd Yag laser. The safety review data is part of the technical presentation and gives some insight into why the system survived the severe environment of temperature and vibration during the flight of Space Shuttle 61-C.

Muckerheide, M. C.↗

Space Shuttle Columbia views the world with imaging radar: The SIR-A experiment

Images acquired by the Shuttle Imaging Radar (SIR-A) in November 1981, demonstrate the capability of this microwave remote sensor system to perceive and map a wide range of different surface features around the Earth. A selection of 60 scenes displays this capability with respect to Earth resources - geology, hydrology, agriculture, forest cover, ocean surface features, and prominent man-made structures. The combined area covered by the scenes presented amounts to about 3% of the total acquired. Most of the SIR-A images are accompanied by a LANDSAT multispectral scanner (MSS) or SEASAT synthetic-aperture radar (SAR) image of the same scene for comparison. Differences between the SIR-A image and its companion LANDSAT or SEASAT image at each scene are related to the characteristics of the respective imaging systems, and to seasonal or other changes that occurred in the time interval between acquisition of the images.

Ford, J. P.↗

Recovery of the Space Shuttle Columbia Avionics

Lessons Learned: a) Avionics data can playa critical role in the investigation of a "close call" or accident. b) Avionics designers should think about the role their systems might play in an investigation. c) Know your data, down to the bit level. d) Know your spacecraft - follow the data. e) Internal placement of circuit cards can affect their survivability. f) Think about how to reconstruct nonvolatile memory (e.g. serialize IC's, etc.) g) Use of external assets can aid in extracting data from avionics.

Hames, Kevin L.↗

Aeromedical Lessons Learned from the Space Shuttle Columbia Accident Investigation

This slide presentation provides an update on the Columbia accident response presented in 2005 with additional information that was not available at that time. It will provide information on the following topics: (1) medical response and Search and Rescue, (2) medico-legal issues associated with the accident, (3) the Spacecraft Crew Survival Integrated Investigation Team Report published in 2008, and (4) future NASA flight surgeon spacecraft accident response training.

Chandler, Mike↗