Evaluation of RSRM case hardware fretting concerns

Fretting corrosion was first noted on Shuttle flight STS-26. This flight was the first usage of the Redesigned Solid Rocket Motor (RSRM). The occurrence of fretting has since been observed on both the field and factory joints of the RSRM. Fretting is a form of corrosion that occurs at the interface between contacting, highly loaded, metal surfaces when exposed to slight relative vibratory motions. The engineering effort performed to evaluate the effect of fretting on the RSRM case hardware is summarized. Based on the results of this evaluation, several conclusions were made concerning flight safety. Also, recommendations were made concerning trending the effects of multiple generations of fretting damage.