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Columbia Accident Investigation Board Report. Volume Four

This is Volume Four of a set of six reports produced by NASA and other organizations which were provided to the Columbia Accident Investigation Board (CAIB) in support of its inquiry into the February 1, 2003 destruction of the Space Shuttle Columbia. The Technical Documents included in this volume are: Appendix F.1 Water Absorption by Foam; Appendix F.2 Follow the TPS; Appendix F.3 MADS Sensor Data; Appendix F.4 ET Cryoinsulation; Appendix F.5 Space Shuttle STS-107 Columbia Accident Investigation, and External Tank Working Group Final Report - Volume 1.

CRYOINSULATION↗

Characterization of Space Shuttle External Tank Thermal Protection System (TPS) Materials in Support of the Columbia Accident Investigation

NASA suffered the loss of the seven-member crew of the Space Shuttle Columbia on February 1, 2003 when the vehicle broke apart upon re-entry to the Earth's atmosphere. The final report of the Columbia Accident Investigation Board (CAIB) determined that the accident was caused by a launch ascent incident-a suitcase-sized chunk of insulating foam on the Shuttle's External Tank (ET) broke off, and moving at almost 500 mph, struck an area of the leading edge of the Shuttle s left wing. As a result, one or more of the protective Reinforced Carbon-Carbon (RCC) panels on the wing leading edge were damaged. Upon re-entry, superheated air approaching 3,000 F breached the wing damage and caused the vehicle breakup and loss of crew. The large chunk of insulating foam that broke off during the Columbia launch was determined to come from the so-called bipod ramp area where the Shuttle s orbiter (containing crew) is attached to the ET. Underneath the foam in the bipod ramp area is a layer of TPS that is a cork-filled silicone rubber composite. In March 2003, the NASA Marshall Space Flight Center (MSFC) in Huntsville, Alabama received cured samples of the foam and composite for testing from the Michoud Assembly Facility (MAF) in New Orleans, Louisiana. The MAF is where the Shuttle's ET is manufactured. The foam and composite TPS materials for the ET have been well characterized for mechanical property data at the super-cold temperatures of the liquid oxygen and hydrogen fuels used in the ET. However, modulus data on these materials is not as well characterized. The TA Instruments 2980 Dynamic Mechanical Analyzer (DMA) was used to determine the modulus of the two TPS materials over a range of -145 to 95 C in the dual cantilever bending mode. Multi-strain, fixed frequency DMA tests were followed by multi-frequency, fixed strain tests to determine the approximate bounds of linear viscoelastic behavior for the two materials. Additional information is included in the original extended abstract.

Wingard, Charles D.↗

Renewed Commitment to Excellence: An Assessment of the NASA Agency-Wide Applicability of the Columbia Accident Investigation Board Report

The Space Shuttle fleet has been grounded since the Columbia accident. As a result, 'Return to Flight' has become not just a phrase but a program and the global of virtually everyone associated with NASA. Even those who are not affiliated with the Shuttle Program are looking forward to the safe and successful completion of the next Shuttle mission. In this recovery process, NASA will be guided by the Report of the Columbia Accident Investigation Board (CAIB). The CAIB was an investigating body, convened by NASA Administrator O'Keefe the day of the Columbia accident, according to procedures established after the loss of Space Challenger.

SPACE SHUTTLE COLUMBIA↗

Air Safety Spinoffs

Weight saving-even a matter of a few pounds-is an important consideration in airplane design and . construction. Boeing saved 200 pounds simply by substituting a new type of compressed gas cylinder on their 747 commercial airliners. For quickly evacuating passengers in the event of a ground emergency the 747 escape chutes allow ' passengers to slide to safety from the two-story height of the cabin deck. The chutes pop out of exitways and are automatically inflated in seconds by compressed air stored in pressure vessels. Boeing's weight saving resulted from a recent changeover to a new type of pressure vessel built by Structural Composites Industries Inc. of Azusa, Cal. The company employs technology originally developed for rocket motor casings; the cylinders are constructed by winding fibers around an aluminum liner. This technique offers high strength for very low weight-in this case 60 percent less than the pressure vessels earlier used on the 747. Another contribution to improved air safety is an underwater locator device. Called the "Pinger," it uses sonar techniques to locate aircraft crashed in water-or, more specifically, to recover the flight recorder aboard the airplane. Its recovery provides clues as to what caused the accident and suggests measures to prevent similar future occurrences. Until recently, there was no way to recover flight recorders aboard aircraft lost in water crashes. The Pinger, now serving 95 percent of the airline industry, provides an answer. Key element of the Pinger system is a small, battery-powered transmitter, or homing beacon, included as part of the recorder package. For as long as 30 days, the transmitter sends out an acoustic signal from water depths up to 20,000 feet. The other element of the system is a receiver, used by search crews to home in on the transmitter's signal. Originating as a U.S. Navy project, this device was refined and further developed by NASA's Langley Research Center to retrieve submerged nose cones from research rockets. NASA's contractor for the transmitter portion of the system was Dukane Corp., St. Charles, Ill. who subsequently developed the commercial version.

Source record↗

Measuring Positions of Objects using Two or More Cameras

An improved method of computing positions of objects from digitized images acquired by two or more cameras (see figure) has been developed for use in tracking debris shed by a spacecraft during and shortly after launch. The method is also readily adaptable to such applications as (1) tracking moving and possibly interacting objects in other settings in order to determine causes of accidents and (2) measuring positions of stationary objects, as in surveying. Images acquired by cameras fixed to the ground and/or cameras mounted on tracking telescopes can be used in this method. In this method, processing of image data starts with creation of detailed computer- aided design (CAD) models of the objects to be tracked. By rotating, translating, resizing, and overlaying the models with digitized camera images, parameters that characterize the position and orientation of the camera can be determined. The final position error depends on how well the centroids of the objects in the images are measured; how accurately the centroids are interpolated for synchronization of cameras; and how effectively matches are made to determine rotation, scaling, and translation parameters. The method involves use of the perspective camera model (also denoted the point camera model), which is one of several mathematical models developed over the years to represent the relationships between external coordinates of objects and the coordinates of the objects as they appear on the image plane in a camera. The method also involves extensive use of the affine camera model, in which the distance from the camera to an object (or to a small feature on an object) is assumed to be much greater than the size of the object (or feature), resulting in a truly two-dimensional image. The affine camera model does not require advance knowledge of the positions and orientations of the cameras. This is because ultimately, positions and orientations of the cameras and of all objects are computed in a coordinate system attached to one object as defined in its CAD model.

Klinko, Steve↗

Lessons Learned From The EMU Fire and How It Impacts CxP Suit Element Development and Testing

During testing a Space Shuttle Extravehicular Mobility Unit (EMU) pressure garment and life-support backpack was destroyed in a flash fire in the Johnson Space Center's Crew systems laboratory. This slide presentation reviews the accident, probable causes, the lessons learned and the effect this has on the testing and the environment for testing of the Space Suit for the Constellation Program.

Metts, Jonathan↗

High Speed Mobility Through On-Demand Aviation

Game changing advances come about by the introduction of new technologies at a time when societal needs create the opportunity for new market solutions. A unique opportunity exists for NASA to bring about such a mobility revolution in General Aviation, extendable to other aviation markets, to maintain leadership in aviation by the United States. This report outlines the research carried out so far under NASA's leadership towards developing a new mobility choice, called Zip Aviation1,2,3. The feasibility, technology and system gaps that need to be addressed, and pathways for successful implementation have been investigated to guide future investment. The past decade indicates exciting trends in transportation technologies, which are quickly evolving. Automobiles are embracing automation to ease driver tasks as well as to completely control the vehicle with added safety (Figure 1). Electric propulsion is providing zero tail-pipe emission vehicles with dramatically lower energy and maintenance costs. These technologies have not yet been applied to aviation, yet offer compelling potential benefits across all aviation markets, and in particular to General Aviation (GA) as an early adopter market. The benefits of such an adoption are applicable in the following areas: 􀁸 Safety: The GA market experiences accident rates that are substantially higher than automobiles or commercial airlines, with 7.5 fatal accidents per 100 million vehicle miles compared to 1.3 for automobiles and.068 for airlines. Approximately 80% of these accidents are caused by some form of pilot error, with another 13% caused by single point propulsion system failure. 􀁸 Emissions: Environmental constraints are pushing for the elimination of 100Low Lead (LL) fuel used in most GA aircraft, with aviation fuel the #1 source of lead emissions into the environment. Aircraft also have no emission control systems (i.e. no catalytic converters etc.), so they are gross hydrocarbon polluters compared to automobiles. 􀁸 Community Noise: Hub and smaller GA airports are facing increasing noise restrictions, and while commercial airliners have dramatically decreased their community noise footprint over the past 30 years, GA aircraft noise has essentially remained same, and moreover, is located in closer proximity to neighborhoods and businesses. 􀁸 Operating Costs: GA operating costs have risen dramatically due to average fuel costs of over $6 per gallon, which has constrained the market over the past decade and resulted in more than 50% lower sales and 35% less yearly operations. Infusion of autonomy and electric propulsion technologies can accomplish not only a transformation of the GA market, but also provide a technology enablement bridge for both larger aircraft and the emerging civil Unmanned Aerial Systems (UAS) markets. The NASA Advanced General Aviation Transport Experiments (AGATE) project successfully used a similar approach to enable the introduction of primary composite structures and flat panel displays in the 1990s, establishing both the technology and certification standardization to permit quick adoption through partnerships with industry, academia, and the Federal Aviation Administration (FAA). Regional and airliner markets are experiencing constant pressure to achieve decreasing levels of community emissions and noise, while lowering operating costs and improving safety. But to what degree can these new technology frontiers impact aircraft safety, the environment, operations, cost, and performance? Are the benefits transformational enough to fundamentally alter aircraft competiveness and productivity to permit much greater aviation use for high speed and On-Demand Mobility (ODM)? These questions were asked in a Zip aviation system study named after the Zip Car, an emerging car-sharing business model. Zip Aviation investigates the potential to enable new emergent markets for aviation that offer "more flexibility than the existing transportation solutions." These studies indicate that autonomy and electric propulsion technology infusions offer a unique opportunity to provide breakthrough capabilities for new high speed, on-demand travel alternatives that can leapfrog the need for future expensive ground-based infrastructure investment. At the same time, such investments offer a method of laying the foundation for these technologies to be incubated for commercial aviation at lower cost, and with lower initial certification thresholds due to the relatively poor capabilities of GA aircraft to permit early adoption and private market capitalization by rapid technology accelerations, as depicted in Figure 2.

Moore, Mark D.↗

Space Biology and Medicine: Space and Its Exploration - Volume I

Perhaps one of the greatest gifts that has been given to the people of the world in the last few hundred years has been an emerging sense of the place of our planet and its inhabitants within the context of the vast universe. Our knowledge of the rest of the universe has not come quickly, nor was the process of attaining it only recently begun; however, the unprecedented acceleration of that process has benefitted from a fundamental new aspect of our species that has only manifested itself in the last 30 years or so, the ability to travel in space. Before the space age, the Universe was studied only through observations from the Earth. All that has changed with the beginning of the space age. Machines built by humans have flown to all but one of the nine planets that revolve around our Sun, have ventured billions of miles from the Earth and looked back, and have landed on three other worlds. Spacecraft in orbit around the Earth have viewed the sky at a vast number of electromagnetic wavelengths, detecting the shape of the galaxy and the universe, and even measuring the remnants of the universe's beginning. Human explorers have ventured forth, first for short stays in orbit, then, later, walking upon the Moon and living for long periods in space. As they did so, billions of people on the Earth came to view the Earth in a fundamentally different way, not just as the familiar day to- day backdrop for their lives, but as a small oasis suspended in the night sky above an alien landscape. It is this new view of the Earth that is the true gift of space exploration. Space exploration has at once given us a new perspective on the value of our world, and a new perspective from which to understand how it operates. It has shown us that the Earth is by far the most precious place in the solar system in terms of supporting human life, while revealing that other destinations may still be compelling. The exploration of space has at once become a challenge for humanity to overcome and a path to our common future. But for humanity to embark on this path, we need to understand ourselves in a new environment. As such, an understanding of the biological consequences of and opportunities in space flight is essential. In this, the first volume of a joint U.S./Russian series on space biology and medicine, we describe the current status of our understanding of space and present general information that will prove useful when reading subsequent volumes. Since we are witnesses to the beginning of a new era of interplanetary travel, a significant portion of the first volume will concentrate on the physical and ecological conditions that exist in near and outer space, as well as heavenly bodies from the smallest ones to the giant planets and stars. While space exploration is a comparatively recent endeavor, its foundations were laid much more than 30 years ago, and its history has been an eventful one. In the first part of this volume, Rauschenbach, Sokolskiy, and Gurjian address the "Historical Aspects of Space Exploration" from its beginnings to a present-day view of the events of the space age. The nature of space itself and its features is the focus of the second section of the volume. In the first chapter of the part, "Stars and Interstellar Space," the origin and evolution of stars, and the nature of the portions of space most distant from Earth are described by Galeev and Marochnik. In Chapter 2, Pisarenko, Logachev, and Kurt in "The Sun and Interplanetary Space" bring us to the vicinity of our own solar system and provide a description and discussion of the nearest star and its influence on the space environment that our Earth and the other planets inhabit. In our solar system there are many fascinating objects, remnants of the formation of a rather ordinary star in a rather obscure portion of the galaxy. Historical accident has caused us to be much more curious (and knowledgeable) about "The Inner Planets of the Solar System" than about any of these other objects. In Chapter 3, Marov describes the planets Mercury, Venus, Earth, and Mars, their history and origin, and their environmental conditions, and in Chapter 4 Owen provides similar information about Jupiter, Saturn, Uranus, Neptune, and Pluto, "The Outer Planets of the Solar System." Morrison provides a thorough discussion of "Asteroids, Comets, and Other Small Bodies" in Chapter 5. The understanding of these relics of the formation of the solar system may form the center of our ability to understand the origin of solar systems in general, and of the critical role that the beginning of the solar system had on the prospects for the origin of life and its continued survival and evolution in the face of their recurrent impacts on Earth. In Chapter 6, the first chapter of the third part, Rummel describes the area of "Exobiology," the study of the origin, evolution, and distribution of life in the context of the origin and evolution of the universe. The same processes that have given rise to life on Earth may have given rise to life elsewhere. In Chapter 7, the "Earth and the Biosphere," the nature and function of the Earth are discussed as a specific instance of planetary and biological evolution. The effects of biological processes on the Earth under the influence of human activities are also addressed by Moore and Bartlett in Chapter 7. The final chapter in this section concerns the prospects that life in the universe may be widespread; "SETI," the Search for Extraterrestrial Intelligence, by Billingham and Tarter, presents the arguments for conducting a search for evidence of life elsewhere in the galaxy, and describes the various methods proposed for conducting such a search. While SETI has a distinctly exploration al character, more direct means are available for exploring the solar system around us. The fourth part of the volume addresses this subject of space exploration. Considering the prospects for research on space biology and medicine, the means of providing "Access to Space" are described by Feoktistov and Briggs in Chapter 9. This chapter addresses carriers and launch systems, the unmanned and manned spacecraft that they loft into space, and the task of mission operations by which these precious vessels are monitored, navigated, and controlled. Despite the successes of the past and the capabilities of the present, it is clear that the study of space biology and medicine will be even more rewarding in the future than it has been to date. The work of the next few years that will be undertaken by the U.S. and Russia, both independently and jointly, will focus first on enabling greater capabilities in the exploration of space, and then on using the unique characteristics of the space environment to provide insight and greater understanding into biological systems, their behavior, development, and origin. The chapters of the first volume were written by leaders in their fields from the U.S. and Russia. The material presented summarizes our current understanding of space and its exploration. We understand that the first volume will be of interest not only to medical personnel and biologists, but also to general readers who want information about space beyond their own particular fields of expertise.

Nicogossian, Arnauld E.↗

Piloted Simulator Evaluation Results of Flight Physics Based Stall Recovery Guidance

In recent studies, it has been observed that loss of control in flight is the most frequent primary cause of accidents. A significant share of accidents in this category can be remedied by upset prevention if possible, and by upset recovery if necessary, in this order of priorities. One of the most important upsets to be recovered from is stall. Recent accidents have shown that a correct stall recovery maneuver remains a big challenge in civil aviation, partly due to a lack of pilot training. A possible strategy to support the flight crew in this demanding context is calculating a recovery guidance signal, and showing this signal in an intuitive way on one of the cockpit displays, for example by means of the flight director. Different methods for calculating the recovery signal, one based on fast model predictive control and another using an energy based approach, have been evaluated in four relevant operational scenarios by experienced commercial as well as test pilots in the Vertical Motion Simulator at NASA Ames Research Center. Evaluation results show that this approach could be able to assist the pilots in executing a correct stall recovery maneuver.

Lombaerts, Thomas↗

Creating Formal Characterizations of Routine Contingency Management in Commercial Aviation

The identification, modelling, and analysis of root causes of accidents and incidents dominate conventional safety management approaches. However, the effect of humans’ safety-producing behavior on the overall resilience of the system is often neglected. Additionally, emerging aviation markets are giving rise to concepts of operation, such as urban air mobility and optionally piloted air cargo operations, that are leading to a shift in locus of control between humans and automation. Without an understanding of the human contribution to safety, it is difficult to assess the effects of these novel role allocations on overall system safety. In this work, safety-producing behaviors are identified and abstracted into resilient performance strategies. Production rules that encapsulate these strategies are then generated and classified in the Soar cognitive architecture. The strategies are then applied to a remotely-operated air cargo example to demonstrate how safe learning is facilitated. The learned rules and strategies are then formally verified.

Safety Critical Systems↗

How Humans Contribute to Safety

We have all heard, and much too often, how human error is the leading cause of accidents. What we haven’t been hearing is how humans produce safety far more often than reduce safety. Before we embark on developing technologies to replace the error-prone human, it behooves us to understand how humans produce safety lest we lose that primary source of resilience in our aviation system.

safety↗

ECAR-6332 Rev 3 RELAP5-3D Thermal-Hydraulic Analysis of MARVEL Microreactor - Final Design

This document reports the thermal hydraulic analyses results for the MARVEL microreactor, final design, including dry criticality, normal operation, operational transients and a set of very-low probability transients caused by accident conditions. The ultimate scope of this document is to demonstrate the MARVEL microreactor thermal hydraulic performances and its inherent safety. First, the list of the operational and accidental transients with the corresponding acceptance criteria are recalled. Then, details of the final design, the key input parameters, the assumptions, and the methodology used for performing the deterministic safety analyses are presented. Finally, the analyses results are provided, demonstrating the satisfaction of the corresponding acceptance criteria.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

Report of Apollo 204 Review Board

The Nation's space program requires that man and machine achieve the highest capability to pursue the exploration of space. The Apollo 204 Review Board was charged with the responsibility of reviewing the circumstances surrounding the accident, reporting its findings relating to the cause of the accident, and formulating recommendations so that inherent hazards are reduced to a minimum. The Board is very concerned that its description of the defects in the Apollo Program that led to the condition existing at the time of the Apollo 204 accident will be interpreted as an indictment of the entire manned space flight program and a castigation of the many people associated with that program. This report, rather than presenting a total picture of that program, is concerned with the deficiencies uncovered.

Source record↗

The Analysis of the Contribution of Human Factors to the In-Flight Loss of Control Accidents

In-flight loss of control (LOC) is currently the leading cause of fatal accidents based on various commercial aircraft accident statistics. As the Next Generation Air Transportation System (NextGen) emerges, new contributing factors leading to LOC are anticipated. The NASA Aviation Safety Program (AvSP), along with other aviation agencies and communities are actively developing safety products to mitigate the LOC risk. This paper discusses the approach used to construct a generic integrated LOC accident framework (LOCAF) model based on a detailed review of LOC accidents over the past two decades. The LOCAF model is comprised of causal factors from the domain of human factors, aircraft system component failures, and atmospheric environment. The multiple interdependent causal factors are expressed in an Object-Oriented Bayesian belief network. In addition to predicting the likelihood of LOC accident occurrence, the system-level integrated LOCAF model is able to evaluate the impact of new safety technology products developed in AvSP. This provides valuable information to decision makers in strategizing NASA's aviation safety technology portfolio. The focus of this paper is on the analysis of human causal factors in the model, including the contributions from flight crew and maintenance workers. The Human Factors Analysis and Classification System (HFACS) taxonomy was used to develop human related causal factors. The preliminary results from the baseline LOCAF model are also presented.

Ancel, Ersin↗

Columbia Accident Investigation Board. Volume One

The Columbia Accident Investigation Board's independent investigation into the February 1, 2003, loss of the Space Shuttle Columbia and its seven-member crew lasted nearly seven months. A staff of more than 120, along with some 400 NASA engineers, supported the Board's 13 members. Investigators examined more than 30,000 documents, conducted more than 200 formal interviews, heard testimony from dozens of expert witnesses, and reviewed more than 3,000 inputs from the general public. In addition, more than 25,000 searchers combed vast stretches of the Western United States to retrieve the spacecraft's debris. In the process, Columbia's tragedy was compounded when two debris searchers with the U.S. Forest Service perished in a helicopter accident. This report concludes with recommendations, some of which are specifically identified and prefaced as 'before return to flight.' These recommendations are largely related to the physical cause of the accident, and include preventing the loss of foam, improved imaging of the Space Shuttle stack from liftoff through separation of the External Tank, and on-orbit inspection and repair of the Thermal Protection System. The remaining recommendations, for the most part, stem from the Board's findings on organizational cause factors. While they are not 'before return to flight' recommendations, they can be viewed as 'continuing to fly' recommendations, as they capture the Board's thinking on what changes are necessary to operate the Shuttle and future spacecraft safely in the mid- to long-term. These recommendations reflect both the Board's strong support for return to flight at the earliest date consistent with the overriding objective of safety, and the Board's conviction that operation of the Space Shuttle, and all human space-flight, is a developmental activity with high inherent risks.

SPACE SHUTTLE COLUMBIA↗

A dangerous seaplane landing condition

A peculiar phenomena in seaplane landing is observed and reported. The seaplane having executed a normal fast landing at low incidence, a forward movement of the control stick effected an unusual condition in that the seaplane left the water suddenly in an abnormal attitude. The observations describing this phenomena are offered as a warning against possible accident and as a conjectural cause of seaplane landing accidents of a certain kind.

PRESSURE DISTRIBUTION - FLOAT BOTTOMS↗

Software Programs Derive Measurements from Photographs

Even under the most unfortunate circumstances, NASA continues on a path of innovation. After the Space Shuttle Columbia reentered the atmosphere on February 1, 2003, it experienced a catastrophic failure, and the entire crew and vehicle were lost. For the two weeks prior to the accident, Columbia STS-107 was on a mission to perform physical, life, and space sciences research in the unique environment of microgravity. Following the accident, the remaining shuttles - Endeavor, Atlantis, and Discovery - were grounded, and an intense investigation ensued. The Columbia Accident Investigation Board spent nearly 7 months examining the cause of the accident and determining what would ensure a safe return to flight. To this end, investigators performed an extensive review down five analytic paths: aerodynamic, thermodynamic, sensor data timeline, debris reconstruction, and imaging. As part of the evaluation of all the available imagery from Columbia's ascent, orbit, and entry, investigators needed a new method for analyzing still video images to determine the size of the material that fell from Columbia, as well as the distance that the material traveled. John Lane, a scientist at Kennedy Space Center, devised a software program to calculate the unknown dimension of the material in the images, and soon after the investigation was complete, continued to enhance the technology. Eventually, the program that assisted in the Columbia investigation became available for licensing.

Source record↗

The classification of wind shears from the point of view of aerodynamics and flight mechanics

A study of international statistical data shows that in about three quarters of all serious accidents which occurred with jet propelled airliners wind shear was either one of the main causes of the accident or represented a major contributory cause. Wind shear related problems are examined. The necessity of a use of different concepts, definitions, and divisions is explained, and the concepts and definitions required for the division of wind and wind shear into different categories is discussed. A description of the context between meteorological and aerodynamics-flight mechanics concepts, definitions, and divisions is also provided. Attention is given to wind and wind components, general characteristics of wind shear and the meteorological terms, the basic types of wind shear for aerodynamics-flight mechanics investigations, special types of wind shear for aerodynamics-flight mechanics investigations, and possibilities regarding a change of the wind component.

Seidler, Fritz↗