Static measurement of the thickness of the ablative coating of the solid rocket boosters

The Solid Rocket Boosters (SRB's) used to launch the Space Shuttle are coated with a layer of ablative material to prevent thermal damage when they reenter the earth's atmosphere. The coating consists of a mixture of cork, glass, and resin. A new coating (Marshall Convergent Coating, MCC-2) was recently developed that is environmentally complaint. The coating must meet certain minimum thickness standards in order to protect the SRB. The coating is applied by a robot controlled nozzle that moves from the bottom to top, as the rocket part rotates on a table. Several coats are applied, building up to the desired thickness. Inspectors do a limited amount of destructive 'wet' testing. This involves an inspector inserting a rod in the wet coating and removing the rod. This results in a hole that, of course, must be patched later. The material is cured and the thickness is measured. There is no real-time feedback as the coating is being applied. Although this might seem like the best way to control thickness, the problems with 'blowback' (reflected material covering the sensor) are formidable, and have not been solved. After the thermal coating is applied, a protective top coat is applied. The SRB part is then placed in a oven and baked to harden the surface. The operations personnel then measure the thickness of the layer using the Kaman 7200 Displacement Measuring System. The probe is placed on the surface. One person (the inspector) reads the instrument, while another(the technician) records the thickness. Measurements are taken at one foot intervals. After the measurements are taken, the number of low readings is tabulated. If more than 10 percent of the points fall below the minimum value, there is a design review, and the part may be stripped of coating, and a new coating is applied. There is no other analysis.