Overview of High-Resolution Nondestructive Inspection of the Space Shuttle External Tank (ET) Spray-on-Foam Insulation (SOFI) and Acreage Heat tiles using Focused, Synthetic and Holographical Millimeter Wave Techniques

Space Shuttle Columbia's catastrophic failure has been attributed to a piece of spray-on-foam insulation (SOFI) that was dislodged from the external tank (ET) and struck the leading edge of the left wing. A piece of SOFI was also dislodged in the recent Space Shuttle Discovery's flight. From immediately after the Columbia accident, microwave and millimeter wave nondestructive testing methods were considered as potential effective inspection tools for evaluating the integrity of the SOFI. To this end and as a result of these efforts, both real-focused, synthetic focusing and holographical techniques, at a wide range of frequencies covering 24 GHz to 150 GHz, have been developed for this purpose. Images of various complex SOFI panels with a wide range of embedded anomalies (representing real potential defects) have been produced using these techniques, including relatively small anomalies located near complex structural features representative of the external tank. These real-focused and 3D holographical images have effectively demonstrated the utility of these methods for SOFI inspection as being viable, robust, repeatable, simple, portable and relatively inexpensive (tens of $K as opposed to hundreds of $K). In addition, the potential viability of these methods for inspecting acreage heat tiles have has been demonstrated. This paper presents an overview of these activities, representative images of these panels using all of the imaging techniques used and a discussion of the practical attributes of these inspection methods.