High-resolution images taken from a ground-based Air
Force tracking camera in the southwestern U.S. show
serious structural damage to the inboard leading edge of
Columbia's left wing, as the crippled orbiter flew
overhead about 60 sec. before the vehicle broke up over
Texas killing the seven astronauts on board Feb. 1.
According to sources close to the investigation, the
images, under analysis at the Johnson Space Center in
Houston, show a jagged edge on the left inboard wing
structure near where the wing begins to intersect the
fuselage. They also show the orbiter's right aft yaw
thrusters firing, trying to correct the vehicle's
attitude that was being adversely affected by the left
wing damage. Columbia's fuselage and right wing appear
normal. Unlike the damaged and jagged left wing section,
the right wing appears smooth along its entire length.
The imagery is consistent with telemetry.
The ragged edge on the left leading edge, indicates
that either a small structural breach--such as a
crack--occurred, allowing the 2,500F reentry heating to
erode additional structure there, or that a small
portion of the leading edge fell off at that location.
Either way, the damage affected the vehicle's flying
qualities as well as allowed hot gases to flow into
critical wing structure--a fatal combination.
It is possible, but yet not confirmed, that the impact
of foam debris from the shuttle's external tank during
launch could have played a role in damage to the
wing leading edge, where the deformity appears in USAF
imagery.
If that is confirmed by the independent investigation
team, it would mean that, contrary to initial shuttle
program analysis, the tank debris event at launch played
a key role in the root cause of the accident.
Another key factor is that the leading
edge of the shuttle wing, where the jagged shape was
photographed, transitions from black thermal protection
tiles to a much different mechanical system made of
reinforced carbon-carbon material that is bolted on,
rather than glued on as the tiles are.
This means that in addition to the possible failure
of black tile at the point where the wing joins the
fuselage, a failure involving the attachment mechanisms
for the leading edge sections could also be a factor,
either related or not to the debris impact. The actual
front structure of a shuttle wing is flat. To provide
aerodynamic shape and heat protection, each wing is
fitted with 22 U-shaped reinforced carbon-carbon (RCC)
leading-edge structures. The carbon material in the
leading edge, as well as the orbiter nose cap, is
designed to protect the shuttle from temperatures above
2,300F during reentry. Any breach of this leading-edge
material would have catastrophic consequences.
The U-shaped RCC sections are attached to the wing
"with a series of floating joints to reduce loading on
the panels due to wing deflections," according to Boeing
data on the attachment mechanism.
"The [critical heat protection] seal between each
wing leading-edge panel is referred to as a 'tee' seal,"
according to Boeing, and is also made of a carbon
material.
The tee seals allow lateral motion and thermal
expansion differences between the carbon sections and
sections of the orbiter wing that remain much cooler
during reentry.
In addition to debris impact issues, investigators
will likely examine whether any structural bending
between the cooler wing structure and the
more-than-2,000F leading edge sections could have played
a role in the accident. There is insulation packed
between the cooler wing structure and the bowl-shaped
cavity formed by the carbon leading-edge sections.
The RCC leading-edge structures are bolted to the
wing using Inconel fittings that attach to aluminum
flanges on the front of the wing.
The initial NASA Mission Management Team (MMT)
assessment of the debris impact--made on Jan. 18, two
days after launch--noted "The strike appears to have
occurred on or relatively close to the "wing glove" near
the orbiter fuselage.
The term "wing glove" generally refers to the area
where the RCC bolt-on material is closest to the
fuselage. This is also the general area where USAF
imagery shows structural damage.
The second MMT summary analyzing the debris hit was
made on Jan. 20 and had no mention of the leading-edge
wing glove area. That report was more focused on orbiter
black tiles on the vehicle's belly. The third and final
summary issued on Jan. 27 discusses the black tiles
again, but also specifically says "Damage to the RCC
[wing leading edge] should be limited to [its] coating
only and have no mission impact." Investigators in
Houston are trying to match the location of the debris
impact with the jagged edge shown in the Air Force
imagery.
Columbia reentry accident investigators are also
trying to determine if, as in the case of Challenger's
accident 17 years ago, an undesirable materials
characteristic noted on previous flights--in this case
the STS-112 separation of external tank insulation foam
debris--was misjudged by engineers as to its potential
for harm, possibly by using analytical tools and
information inadequate to truly identify and quantify
the threat to the shuttle. As of late last week, NASA
strongly asserted this was not the case, but intense
analysis on that possibility continues.
The shuttle is now grounded indefinitely and the
impact on major crew resupply and assembly flights to
the International Space Station remains under intense
review.
Killed in the accident were STS-107 mission commander
USAF Col. Rick Husband; copilot Navy Cdr. William
McCool; flight engineer Kalpana Chawla; payload
commander USAF Lt. Col. Michael Anderson; mission
specialist physician astronauts Navy Capt. Laurel Clark
and Navy Capt. David Brown; and Israel Air Force Col.
Ilan Ramon.
"We continue to recover crew remains and we are
handling that process with the utmost care, the utmost
respect and dignity," said Ronald Dittemore, shuttle
program manager.
No matter what the investigations show, there are no
apparent credible crew survival options for the failure
Columbia experienced. With the ISS out of reach in a far
different orbit, there were no credible rescue options
even if wing damage had been apparent before
reentry--which it was not.
If, in the midst of its 16-day flight, wing damage
had been found to be dire, the only potential--but still
unlikely--option would have been the formulation over
several days by Mission Control of a profile that could
have, perhaps, reduced heating on the damaged wing at
the expense of the other wing for an unguided reentry,
with scant hope the vehicle would remain controllable to
about 40,000 ft., allowing for crew bailout over an
ocean.
Reentry is a starkly unforgiving environment where
three out of the four fatal manned space flight
accidents during the last 35 years have occurred.
These include the Soyuz 1 reentry accident that
killed cosmonaut Vladimir Komarov in 1967 and the 1971
Soyuz 11 reentry accident that killed three cosmonauts
returning after the first long-duration stay on the
Salyut 1 space station.
The only fatal launch accident has been Challenger in
1986, although Apollo astronauts Gus Grissom, Ed White
and Roger Chaffee were killed when fire developed in
their spacecraft during a launch pad test not involving
launch.
No other accident in aviation history has been seen
by so many eyewitnesses than the loss of
Columbia--visible in five states.
Telemetry and photographic analysis indicate the
breakup of the historic orbiter took place as she slowed
from Mach 20-to-18 across California, Nevada, Arizona
and New Mexico with the loss of structural integrity
205,000 ft. over north-central Texas where most of the
debris fell.
The science-driven STS-107 crew was completing 16
days of complex work in their Spacehab Research Double
module and were 16 min. from landing at Kennedy when
lost. Landing was scheduled for 8:16 a.m. CST.
Abnormal telemetry events in the reentry began at
7:52 a.m. CST as the vehicle was crossing the coast
north of San Francisco at 43 mi. alt., about Mach 20.
The orbiter at this time was in a 43-deg. right bank
completing its initial bank maneuver to the south for
initial energy dissipation and ranging toward the
Kennedy runway still nearly 3,000 mi. away.
That initial bank had been as steep as about 80 deg.
between Hawaii and the California coast, a normal flight
path angle for the early part of the reentry. The
abnormal events seen on orbiter telemetry in Houston
indicate a slow penetration of reentry heat into the
orbiter and damage on the wing, overpowering the flight
control system. Key events were:
* 7:52 a.m. CST: Three left main landing gear
brakeline temperatures show an unusual rise. "This was
the first occurrence of a significant thermal event in
the left wheel well," Dittemore said. Engineers do not
believe the left wheel well was breached, but rather
that hot gases were somehow finding a flow path within
the wing to reach the wheel well.
* 7:53 a.m. CST: A fourth left brakeline strut
temperature measurement rose significantly--about 30-40
deg. in 5 min.
* 7:54 a.m. CST: With the orbiter over eastern
California and western Nevada, the mid-fuselage mold
line where the left wing meets the fuselage showed an
unusual temperature rise. The 60F rise over 5 min. was
not dramatic, but showed that something was heating the
wing fuselage interface area at this time. Wing leading
edge and belly temperatures were over 2,000F. While the
outside fuselage wall was heating, the inside wall
remained cool as normal.
* 7:55 a.m. CST: A fifth left main gear temperature
sensor showed an unusual rise.
* 7:57 a.m. CST: As Columbia was passing over Arizona
and New Mexico, the orbiter's upper and lower left wing
temperature sensors failed, probably indicating their
lines had been cut. The orbiter was also rolling back to
the left into about a 75-deg. left bank angle, again to
dissipate energy and for navigation and guidance toward
Runway 33 at Kennedy, then about 1,800 mi. away.
* 7:58 a.m. CST: Still over New Mexico, the elevons
began to move to adjust orbiter roll axis trim,
indicating an increase in drag on the left side of the
vehicle. That could be indicative of "rough tile or
missing tile but we are not sure," Dittemore said. At
the same time, the elevons were reacting to increased
drag on the left side of the vehicle, the left main
landing gear tire pressures and wheel temperature
measurements failed. This was indicative of a loss of
the sensor, not the explosion or failure of the left
main gear tires, Dittemore believes. The sensors were
lost in a staggered fashion.
* 7:59 a.m. CST: Additional elevon motion is
commanded by the flight control system to counteract
left side drag. The drag was trying to roll the vehicle
to the left, while the flight control system was
commanding the elevons to roll it back to the right.
But the rate of left roll was beginning to overpower
the elevons, so the control system fired two
870-lb.-thrust right yaw thrusters to help maintain the
proper flight path angle. The firing lasted 1.5 sec.
and, along with the tire pressure data and elevon data,
would have been noted by the pilots.
At about this time, the pilots made a short
transmission that was clipped and essentially
unintelligible.
In Mission Control, astronaut Marine Lt. Col. Charles
Hobaugh, the spacecraft communicator on reentry flight
director Leroy Cain's team, radioed "Columbia, we see
your tire pressure [telemetry] messages and we did not
copy your last transmission."
One of the pilots then radioed "Roger," but appeared
to be cut off in mid-transmission by static. For a
moment there were additional static and sounds similar
to an open microphone on Columbia but no transmissions
from the crew.
All data from the orbiter then stopped and the
position plot display in Mission Control froze over
Texas, although an additional 30 sec. of poor data may
have been captured.
Controllers in Mission Control thought they were
experiencing an unusual but non-critical data drop-out.
But they had also taken notice of the unusual buildup of
sensor telemetry in the preceding few minutes.
About 3 min. after all data flow stopped, Hobaugh in
Mission Control began transmitting in the blind to
Columbia on the UHF backup radio system. "Columbia,
Houston, UHF comm. check" he repeated every 15-30 sec.,
but to no avail. In central Texas, thousands of people
at that moment were observing the orbiter break up at
Mach 18.3 and 207,000 ft.
Milt Heflin, chief of the flight director's office,
said he looked at the frozen data plots. "I and others
stared at that for a long time because the tracking
ended over Texas. It just stopped. It was then that I
reflected back on what I saw [in Mission Control] with
Challenger."
The loss of Challenger occurred 17 years and four
days before the loss of Columbia.
"Our landscape has changed," Heflin said. "The space
flight business today is going to be much different than
yesterday.
"It was different after the Apollo fire, it was
different after Challenger."
Columbia, the first winged reusable manned spacecraft
first launched in April 1981, was lost on her 28th
mission on the 113th shuttle flight.
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