[red-beard]

Holy Crap!!!! I did not realize that part of the failure of the O-rings was due to a change in the protective putty material away from one that contained asbestos. And appearently, there is more data than just the shuttle, the Titan-34D failures are also being blamed from changing the putty:

Lost In Space


Posted Aug. 4, 2003


By John Berlau
For Insight Magazine

The National Aeronautics and Space Administration, better known as NASA, said in July that it had found the "smoking gun" that caused the space shuttle Columbia to break apart as it re-entered the Earth's atmosphere on Feb. 1: a piece of foam that had peeled off the external fuel tank and struck the shuttle's wing 1 minute and 22 seconds after liftoff.

But many experts looking at the tragedy that killed seven astronauts say there is a deeper cause. They say that the metaphorical smoking gun should be painted green.

Because of demands that the agency help to front for environmentalism, and under pressure from the Clinton-Gore administration's Environmental Protection Agency (EPA) led by Carol Browner, NASA had stopped using Freon, a fluorocarbon that greens claim damages the ozone layer, in its thermal-insulating foam. NASA found in 1997 after the first launch with the politically correct substitute that the Freon-free foam had destroyed nearly 11 times as many of the shuttle's ceramic tiles as had the foam containing Freon. The politicized foam was less sticky and more brittle under extreme temperatures. But apparently little or nothing was done to resist the environmentalist politicians.

"It was at least a contributing factor, if not a major factor," says Hannes Hacker, an aerospace engineer and former flight controller at NASA's Johnson Space Center in Houston who is affiliated with the Ayn Rand Institute in Irvine, Calif. Hacker tells Insight: "The risk of a piece of debris falling off and causing significant damage to the space shuttle's thermal-protection system was [more than] 10 times greater with the new material than with the old material."

Officials at NASA have confirmed to this magazine that the destructive role of the new foam will be covered in a report on the causes of the space-shuttle disintegration scheduled for release in August. "It's a part of the investigation," says Lt. Col. Tyrone "Woody" Woodyard, spokesman for NASA's Columbia Accident Investigation Board. "The application of the foam is certainly something the board is looking at." Woodyard said he could not comment on specifics until the accident report was released.

NASA, as well as the EPA officials who pressed it to stop using Freon, may have a lot to answer for. In a 1997 "Field Journal" report of the first shuttle launches to use the new foam, NASA mechanical-systems engineer Greg Katnik noted that "there had been significant damage to the [ceramic] tiles" and "the extent of damage at the conclusion of this mission was not 'normal.'" There had been 308 "hits" to the tiles, and 132 were greater than 1 inch, penetrating more than half of the 2-inch tiles. Some slashes were as long as 15 inches. "Over 100 tiles had been removed ... because they were irreparable," according to the report.

Katnik fingered the new foam as a cause of the damage. "It is suspected that large amounts of foam separated from the external tank and impacted the orbiter," he wrote. Since the beginning of the space-shuttle program in the 1980s, the shuttle tanks had been sprayed with insulating material to keep the nitrogen and oxygen fuels from overheating. But Katnik warned directly that "because of NASA's goal to use environmentally friendly products, a new method of 'foaming' the external tank had been used for this mission." He called officially for "investigating the consideration that some characteristics of the new foam may not be known for the ascent environment."

Katnik wasn't the only one to raise doubts about the new "environmentally correct" foam. According to Knight Ridder News Service, a retired engineering manager for Lockheed Martin Corp., the company that assembles NASA's tanks, said at a conference last September that developing the Freon-free foam had "been much more difficult than anticipated" and that the new foam "resulted in unanticipated program impacts, such as foam loss during flight." The manager noted that on the 1997 launch, the same one Katnik had studied, NASA had to replace nearly 11 times more damaged tiles than after a previous mission that had used the old foam.

With all these warnings from experts, why did NASA go ahead with the less-safe foam? And who is to blame for putting environmentalism ahead of the lives of our astronauts? Much is unclear about where responsibility rests. Browner's EPA aggressively was pushing industry and government agencies to stop using Freon, going beyond what the Montreal Protocol treaty required. Yet NASA scientists also had been drawn into hyping the scare about the ozone layer being damaged by fluorocarbons.