Large Scale Shearography Inspection of the Space Shuttle External Fuel Tank

Shearography was successfully used to inspect the damaged region of ET122 for nonvisible damage. The shearography inspection was extensive covering over 3100 square feet of foam and lasting 9 months. Most foam damage was visible and shearography results confirmed that foam damage in visibly impacted regions did not extend outside the area with visible damage. Of the 21 nonvisible defect indications detected with shearography, none were determined to be actual foam damage. Inspections were intentionally conservative since no experience base was available for debris damaged foam. Shearography results were used in conjunction with tactile and visual inspection to support the acceptance of the foam application allowing the tank to move forward for refurbishment.