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Researchers Still Tackling Shuttle Foam Problems

Foam shredding has been a problem since STS 1 (Columbia) was launched in 1981.
by Staff Writers
Ames IO (SPX) March 5, 2006
Iowa State University researchers are studying how X-ray backscatter imaging and computer simulations can help NASA examine the insulating foam on the space shuttle's giant external fuel tank to find any defects that could threaten future missions.

Unlike traditional X-rays that make images by transmitting radiation through an object to a detector, backscatter technology makes images based on the electromagnetic radiation deflected back by the objects examined.

Pieces of foam fell from shuttle Columbia's tank during its January 2003 launch, causing serious damage to the spacecraft's left wing and resulting in the shuttle's destruction when it re-entered Earth's atmosphere on Feb. 1. The accident killed all seven astronauts aboard and grounded the shuttle while NASA engineers worked to solve the foam problem.

When shuttle Discovery finally lifted off last July, more foam chunks fell from the main fuel tank and sent engineers looking for more answers. The problem threatens to delay the next scheduled launch of Discovery in May.

Late last year, NASA asked Joe Gray, of Iowa State's Center for Nondestructive Evaluation, and his research team, to do a three-month study to answer two lingering questions about NASA's foam testing: They wanted to know more about the ability of X-ray technology to detect bubbles when layers of shuttle foam curve around corners, and they wanted to know more about the technology's ability to see any bubbles near the foam's layer lines.

The spray-on foam that insulates and protects the shuttle's super-cold external fuel tank is applied in thin layers. The top of the layer dries to a bumpy crust, marking each layer like rings mark a tree trunk.

The researchers have been taking X-ray images of foam samples and loading that information into a computer simulation program. Then they ran simulations that model the X-ray technology's ability to find defects in the foam.

Gray said he expects to send NASA a final report of the research results later this month.

"Our job has long been to do research, find new inspection technologies and develop a better understanding of those technologies," said R. Bruce Thompson, the center's director. "Now we're seeing those technologies put into practice on a real and national problem."

For the past four years, CNE researchers have been working on 17 NASA research projects that have focused on finding new technologies to monitor and inspect spacecraft.

Related Links
ISU Center For Nondestructive Evaluation
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Discoverys Main Tank Arrives At The Cape
Cape Canaveral FL (SPX) March 1, 2006
Cape Canaveral FL (SPX) March 1, 2006 Shuttle Discovery's main fuel tank arrived by barge at NASA's Kennedy Space Center on Wednesday afternoon, after leaving its assembly facility in Michoud, La., last Saturday.







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