Failure Analysis of Main Flame Deflector Nelson Studs

NASA Structures engineers submitted two Nelson refractory studs from the main flame deflector at Launch Complex (LC) 39 A for analysis when they were observed to be missing a significant amount of material after launch. The damaged stud and an unused comparative stud were analyzed by macroscopic and microscopic examination along with metallographic evaluation of the microstructure. The stud lost material due to a combination of erosion and corrosion. Plain carbon steel readily forms an oxide layer in the coastal launch environment at Kennedy Space Center. The blast during a launch removes this brittle oxide layer, which then forms again post-launch, thereby further removing material. No indications of melting were observed.