High-Resolution Millimeter Wave Detection of Vertical Cracks in the Space Shuttle External Tank (ET) Spray-on-Foam Insulation (SOFI)

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 Space Shuttle Discovery's flight in 2005 and recently a crack was detected in its ET foam prior to its successful launch. Millimeter wave nondestructive testing methods have been considered as potential effective inspection tools for evaluating the integrity of the SOFI. Recently, in a specific investigation into the potential of these methods for detecting vertical cracks in SOFI was explored using a focused millimeter wave reflectometer at 150 GHz. The results showed the capability of these methods for detecting tight vertical cracks (also as a function of crack opening dimension) in exposed SOFI panels and while covered by a piece of SOFI ramp simulating a more realistic and challenging situation. Some crack-like anomalies were also detected in a blind SOFI panel. This paper presents the background for these techniques as well as representative images of the vertical crack in the SOFI panel, crack-like anomalies in the blind panel and a discussion of the practical attributes of these inspection methods.