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Observational Analysis E1B
07/15/2004
The
Probability of Damage to the Space Shuttle From Foam Debris Impact
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Fig.
OA-E1B-1

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Fig.
OA-E1B-1 shows the directions of the positive X, Y and Z coordinates as
they relate to the Space Shuttle. The actual location of the axis
would intersect the vehicle C.G. more towards the center of the shuttle.
Fig. OA-E1B-3 gives the approximate orientation of the shuttle at 82 seconds
after launch. Although most people would assume that the ascent
velocity vector falls inline with the longitudinal X axis, flight
parameters such as sideslip and angle of attack are important during
ascent just as they are during reentry. As the vehicle travels past
Mach 1 shock waves
form around all of the leading edge surfaces of the various components
that make up the stack.
Fig. OA-E1B-7 shows two possible different trajectories for foam debris from
the forward bipod attachment location. Because there is no video
that clearly shows debris impacting the WLE RCC Panel 8 or 9, it may
have also hit the rear bipod.
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Fig. OA-E1B-2
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Fig. OA-E1B-2 is a still from the debris impact video that
reportedly showed exactly how and when the Columbia was damaged.
The first analysis done on the debris impact were based on the
presumption that if debris hit the wing at all, the impact location
would have been well onto the underside of the wing and not at the
leading edge. When viewing the video from this angle it's easy
to understand why there was so much debate about the impact
location.
Although the debris does appear to impact
something under the left wing and break apart it is nearly
impossible to determine exactly what. The video close up seems
to show the object moving past the leading edge and much further out
towards the wing tip than RCC panels 6 through 9. The aft
bipod attachment is an excellent possibility for an impact location
based on the initial trajectory. However, even that is
difficult to tell from the current angle.
View
the Ascent Impact Video |
Probability
of debris impact:
All
of the initial video clip segments and still photos released by
NASA of the Columbia when the debris impact event occurred
showed the shuttle stack with a straight up vertical
orientation. This turned out to be incorrect.
Fig. OA-E1B-3
shows the approximate orientation of the Columbia stack at 81.8
seconds after launch. It also shows what the shock wave
arrangement might look like for the different components of the
stack at Mach 2.5.
During
ascent as the shuttle stack surpasses Mach 1 shockwaves begin to
form around all of the leading edge surfaces. The properties of the shockwaves will
change with the velocity of the shuttle, the atmospheric density
etc. The shockwaves from the different components of the
stack will interfere with or impinge on each other also changing the flow
patterns around the components.
Any foam or other debris that
breaks free from one of the surfaces of the shuttle stack
between the orbiter and the ET will
be acted on by both boundary layer flows and centrifugal forces
if the shuttle takes on a curved trajectory. Aerodynamic
effects on loose debris:
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Fig. OA-E1B-3

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The
factors which affect how a piece of foam debris will act after
it breaks free from the External Tank (ET) change tremendously
during every second of ascent flight. This is
because the shuttle transitions to supersonic flight very
quickly and the shuttle stack continues to see accelerations of
one kind or another up to orbit insertion.
The probability for an impact
needs to be calculated for virtually every different position of
the shuttle stack during ascent.
Because
the maximum allowable aerodynamic moment (forces) that
may be applied to the Space Shuttle anywhere along the
longitudinal X axis
during any flight mode is no more than 2.5
G's,
it can be assumed that anything attached to the ET anywhere along the longitudinal X
axis during ascent could not possibly see more than between 2
and 3 G's.
Therefore,
with the shuttle stack in the ascent position shown at left, any
piece of foam that would break free from the ET would have a
tendency to be pressed against the tank by a force of 2
to 3 G's. The debris would then slide down along the surface of the
tank.
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An
additional effect of the various shockwaves on the foam debris would
be to help maintain its forward velocity and thereby reduce the difference
in closing speed between the shuttle and the debris. Right now
the official investigation is assuming that the velocity of the
debris went almost to zero just after it separated from the External
Tank creating an impact velocity equal to that of the shuttle stack
itself. The boundary layers associated with the shockwaves
are a source of friction and might help to maintain the forward
velocity of the debris somewhat thereby decreasing the final
impact velocity.
Velocity of Stack - Velocity of Debris = Final Impact Velocity. |
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Fig. OA-E1B-4
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Fig. OA-E1B-4 is a photo of Columbia moving past the vertical
structure of Launch Pad 39A during the launch of STS-107. The
forward and aft bipod attachments are clearly shown in this photo.
A schematic depiction of the bipod locations along with the possible
alternate trajectory is shown in
Fig. OA-E1B-7.
It is virtually always necessary to use
statistics to determine failure trends for any mechanical or
electronic systems. However, statistics can almost always have
a double meaning if not more. In the case of foam debris
damage to the Space Shuttle
Fig. OA-E1B-5 and
OA-E1B-6 would seem to show very little reason to worry about
foam significantly damaging Wing Leading Edge RCC panels. |
Fig. OA-E1B-5

Fig. OA-E1B-6

Fig. OA-E1B-7

The probabilities tabularized in the
following two graphics are based on both Shuttle Program flight history and
engineering analysis. These values are not based on the resistance
of the Thermal Protection System (TPS), either the thermal tiles or RCC
material, to impact and assumes that the TPS is already breached.
The Space Shuttles aluminum skin may not and probably will not suffer a
burn through when the TPS is breached as long as the shuttle is flying
its nominal reentry flight pattern. The probability for burn
through is based on the shuttles structure and the thermal
environment. The probability that the shuttle will be lost from a
burn through is based on what critical structures and components are
located in that area of the shuttle.
For a
breach at the leading edge of the left wing
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Summary
/ Conclusions:
Based on the
analysis above, any piece of foam debris that breaks loose from
the External Tank (ET) will not have a tendency to jump off the
tank surface and immediately move towards other components of the
stack. The 2 to 3
G's holding
the debris to the ET will cause it to slide down the length of the
unit until it collides with another obstruction, such as the rear
bipod attachments, and break up. In order for the debris to
come off the surface of the ET it must be acted on by other
outside forces such as boundary layer flows from the other
shockwaves that create vortexes. The
boundary layer flow from the nose of the shuttle itself would have
been the dominant aerodynamic force in that area and would have
had a tendency to move debris down between the shuttle and the ET
but not back up towards the wings, especially debris that would
need to be physically lifted away from the ET. The
official scenario that has been presented as a vehicle to explain
how a 2.1 lbs. piece of foam created a 12" hole in a shuttle
wing leading edge RCC panel requires that the piece of foam debris immediately
leap from the ET, acquire a speed of 600 to 700
Mi. / Hr, (880 -
1027 Ft. / Sec.), and
take on a trajectory that helps it avoid other obstacles and steers it right to the target.
Based on observing how the piece of foam would have to interact
with the various items that make up the shuttle stack, that whole
scenario seems very unlikely.
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The
piece of foam must be lifted from the ET by a vortex action,
which if it exists at that point during ascent, would be the
result of interactions from the other shock waves. The
vortex, if available, must fight a 2 to
3
G force, (4.2
- 6.3 lbs.), puling the debris back
towards the ET.
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The
linear distance from the point where the foam breaks free to
the #8 RCC Panel is approx. 58
Ft. At the debris velocity of 600
to 700
Mi. / Hr the time of travel for the debris is
only 0.0659 to
0.0565 Sec. This is only the linear distance and does
not account for any path adjustments.
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The
facts are that the debris had to make numerous course
adjustments in order to impact the RCC panel at the precise
angle to cause the damage shown in the official
report. In addition the debris had to be lifted
against a force pushing it towards the ET and away from the
shuttle. Any change of direction the debris makes for
any reason from its initial straight line trajectory causes
it to lose some degree of its forward speed which again is
one of the parameters listed in the official report for
causing damage. 0.0659
Sec. is simply not enough time for a piece of
foam to make that many course corrections and still maintain
a large enough velocity to break through the RCC Panel.
Any piece of foam debris breaking away from the forward
bipod area has at least three different factors working
against its changing direction towards the leading edge of
the wing.
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The starting position for the foam puts it well below the
wing. If the shuttle stack were flying straight and
level with not other influences, the debris would never be
able to reach any part of the wing.
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Fig. OA-E1B-3 shows the Columbia with an inclination of
about 25 to 30° with the vertical. At the elapsed time
of 82 seconds after launch the shuttle was at least
beginning a roll maneuver that would put it into position
for orbit. When the shuttle is beginning to take on
such a parabolic trajectory it is intuitively obvious that
it would be traveling away from anything that fell off of
the External Tank (ET) and setting up a source of
centrifugal acceleration that forces any lose objects
outward away from the shuttle.
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The super sonic shockwave and resulting boundary layer flow
around the wing would have at least a small effect on any
object it encounters. The effect would be to move the
object around and below the wings surface.
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