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Space Science

NASA's Foam Test Offers Lesson in Kinetic Energy 503

Puneet submitted a followup story on the foam test that NASA conducted to get an idea of what sort of damage could be caused by foam falling off the shuttle fuel tank at launch. As it turns out: a lot.
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NASA's Foam Test Offers Lesson in Kinetic Energy

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  • by spiny ( 87740 ) on Thursday June 05, 2003 @08:27AM (#6123012) Homepage Journal
    ... could be possible terorist weapons :)

  • Uh... (Score:5, Funny)

    by Anonymous Coward on Thursday June 05, 2003 @08:28AM (#6123018)
    Foam fell off my shelf the other week.
    Should I be worried?
    • Re:Uh... (Score:5, Funny)

      by doc_traig ( 453913 ) on Thursday June 05, 2003 @08:30AM (#6123037) Homepage Journal
      Depdends. Was your shelf headed upward at a thousand miles an hour?

      (If it was, tell me where you got your shelf.)
  • by Anonymous Coward on Thursday June 05, 2003 @08:30AM (#6123036)
    foam and southern florida to science. I tend to get flashbacks of spring break.
  • Basic Physics (Score:4, Insightful)

    by StAugustineLovesYou ( 678635 ) on Thursday June 05, 2003 @08:31AM (#6123050) Homepage Journal
    F = Ma

    I'm surprised that the impact was ever taken so lightly. Paint chips drill holes into satellites and birds take down planes, any impact, given the forces involved with such vehicles has the potential to be catastrophic.

    • Or perhaps, as mentioned in the FA, K=(1/2)mv^2.

    • Re:Basic Physics (Score:5, Informative)

      by mosschops ( 413617 ) on Thursday June 05, 2003 @08:39AM (#6123118)
      > F = Ma

      It's not really force/acceleration that's important, it's kinetic energy and momentum:

      Kinetic Energy = 0.5 * mass * (velocity^2)
      Momentum = mass * velocity

      So a 1g spec of dirt travelling at 20,000mph has the same momentum as a 1KG block travelling at 20mph - something best avoided!
      • Re:Basic Physics (Score:5, Insightful)

        by Anonymous Coward on Thursday June 05, 2003 @08:57AM (#6123263)
        So a 1g spec of dirt travelling at 20,000mph has the same momentum as a 1KG block travelling at 20mph - something best avoided!

        Not only that, but the 1g spec of dirt has a much smaller surface area than the block, therefore excerting a huge weight per surface area. And that's what punches a hole through you.
      • Re:Basic Physics (Score:2, Insightful)

        by kinnell ( 607819 )
        It's not really force/acceleration that's important, it's kinetic energy and momentum:

        How are kinetic energy and momentum more relevant than force? It all depends on how you do the analysis. The total kinetic energy is irrelevant - only the amount of energy transferred to the wing is important. Quoting e=0.5mv^2 looks good in the article because it highlights the importance of velocity, but saying that energy is important and force isn't is ridiculous, because in this scenario the two quantities are com

      • Re:Basic Physics (Score:3, Informative)

        by xsbellx ( 94649 )

        So a 1g spec of dirt travelling at 20,000mph has the same momentum as a 1KG block travelling at 20mph - something best avoided!

        And that same 1KG block would have to be travelling at 632MPH to have the same kinetic energy!

        K = 1/2m*v^2
        K = 0.5 * 1g * 20000mph^2
        K = 200000000

        Therefore:
        200000000=0.5 * 1000 * mph^2
        40000 = mph^2
        mph = sqrt(40000)
        mph = 632.4555

        Momentum increases artithmetically with velocity where as kinetic energy increase geometrically with velocity.

      • Re:Basic Physics (Score:5, Insightful)

        by Transient0 ( 175617 ) on Thursday June 05, 2003 @09:22AM (#6123473) Homepage
        Yeah, and just as importantly, 1.7 pounds of foam has the same momentum as 1.7 pounds of depleted uranium.

        At one point in the article they actually say that the force was equivalent to catching a basketball thrown at 500 mph. OF COURSE IT IS. It is equivalent to catching ANYTHING thrown at 500 mph which weighs about 1.7 pounds. The only real difference is elasticity(which is almost irrelevant at that velocity) and surface area of impact(the same amount of force to a much smaller area).

        Reminds me of the old trick question you use to catch kids: "What weighs more: a kilogram of bricks or a kilogram of feathers?"
      • by MarcQuadra ( 129430 ) * on Thursday June 05, 2003 @09:59AM (#6123861)
        I just did some rough math and guesswork. It seems the wing took about as much force as if I had driven my Ford Escort into it at 15MPH. That's quite a bit of force!

        I wonder how many Volkswagen Beetles that is?
    • Re:Basic Physics (Score:5, Insightful)

      by mbrod ( 19122 ) on Thursday June 05, 2003 @08:42AM (#6123138) Homepage Journal
      I agree. Anything even touching the shuttle is taboo. Anything touching it at high speeds no matter what the nature of it should have raised bigger alarms than it did.

      I think foam hitting the shuttle not doing any damage was a classic case of wishful thinking. Good engineers like this are exactly the people not suppose to do that kind of thinking.

      Mistake was made but I think a lot will be learnt from it. If you look at some of the future shuttle designs you can see they already place the shuttle on top (in front depends how you look at it) so anything coming off doesn't hit the shuttle. This was a major design flaw having the shuttle in that position to the tanks and they know it.
      • Re:Basic Physics (Score:5, Interesting)

        by Mysticalfruit ( 533341 ) on Thursday June 05, 2003 @08:52AM (#6123221) Homepage Journal
        I think the problem was that the foam had hit the shuttle before and it hadn't caused any damage.

        Because of this, I think the engineers were lulled into thinking "Well, it happened before and it didn't cause any damage, why whould anything change now"

        Tragically, their apathy about the whole situation cost the lives of 7 really smart and talented people.

        In the future when we build the next generation shuttle, they integrate some better sensors that would detect that kind of damage.
        • by mykepredko ( 40154 ) on Thursday June 05, 2003 @10:15AM (#6124027) Homepage
          The impression that I am getting (from this article as well as others) is that intuitively the engineers didn't think the foam collision could cause any damage. I haven't seen anything written indicating that there was any past history with pieces of foam striking the leading edge of the orbiter's wings. I have seen articles indicating that foam has struck the underside tiles and damaged one of the landing gear doors and while the tiles were damaged, none in such a way that the shuttle was ever in danger.

          I would think that the line of thinking was, when the foam separated, it was moving at the same speed as the shuttle itself. Since the shuttle, at time of impact was at 50,000+ feet, the force of air drag on the foam would be negligible and the piece of foam would approximately maintain its speed.

          I seem to remember that it is about 30 feet from the bipod to where the foam struck the orbiter's leading edge, so assuming that the foam travels at approximately the same velocity as when it came off and the shuttle was accellerating at 2.5 Gs, it would take about 1.4 seconds for the foam to hit the leading edge. Using these assumptions, the velocity of the foam at impact, relative to the leading edge, would be 110 ft/sec or roughly 75 mph.

          This doesn't sound too bad - after all, it's foam. Getting hit by a Nerf football that has been thrown hard by somebody close by stings, but it won't break bones or even come close to breaking the skin. If you don't think it could do more than bruise you, then it would be hard to accept that the carbon-carbon leading edge of the orbiter could be damaged.

          I think that this was the level of intuitive analysis that was done. Unfortunately, it wasn't backed up by any kind of quantitative analysis using known facts (such as estimating the speed of the impact from the film and checking it against the intuitive speed of impact) to test whether or not there were grounds for concern.

          myke
          • by Anonymous Coward on Thursday June 05, 2003 @11:58AM (#6124952)
            You say "I would think". Well, if I was a responsible engineer at the time and place, I would have thought of a lot more than either you or they seem to have.

            1) Aerodynamic drag at 50,000 feet is hardly "negligible". Drag is proportional to local atmospheric density times the square of the velocity. Atmospheric density at 50,000 feet is 15% that at sea level. Therefore the drag at that altitude is equal to the drag at sea level at 39% of the speed. In other words (pick a number) 500 mph at 50,000 feet causes the same drag as 195 mph at sea level.

            2) Therefore, not only was the space shuttle ACcelerating, but the foam was DEcelerating - probably a LOT - but the point is, it needs to be taken into consideration.

            3) The foam coating the fuel tank is HARDLY the same as that a nerf ball is made of. It is much more substantial.

            4) As I understand it, the piece of foam that broke off was very likely coated with ice. I think if you got hit by a piece of ice travelling 75 mph (much less at an even higher speed), you would most certainly be injured, and so would the leading edge.

            5) Prior strikes were grazing blows on the surface of the wing. We are postulating a direct hit on the leading edge of the wing, made up of very brittle carbon fiber composite.

            All that said, in the end I don't blame those on the scene as much as those responsible for the crappy concept as a whole. Hopefully I would have thought of the case of a direct strike on the leading edge, and hopefully I would have woken up to danger (albeit maybe too late) when a piece of the shuttle was OBSERVED to part company while in orbit, but my true ire is reserved for whoever is responsible for the design concept as a whole. If the fuel tank was coated with crappy insulation that frequently broke off in chunks during launch, that in itself doesn't constitute a hazard. But as soon as you mount a manned space vehicle directly in the path of the debris, that is just unforgiveably negligible.
      • Re:Basic Physics (Score:4, Insightful)

        by bigpat ( 158134 ) on Thursday June 05, 2003 @10:17AM (#6124058)
        "I think foam hitting the shuttle not doing any damage was a classic case of wishful thinking. Good engineers like this are exactly the people not suppose to do that kind of thinking."

        The fact is that some engineers thought that it might be a problem. And from what I have heard they also had computer simulations showing that the impact could have caused damage. So what happened?

        The publicity for this would suggest that as a whole NASA just didn't figure that this foam hit was a problem. The problem I see is that their minority opinions didn't float up along with the majority report. This is very human, either managment wanted to or was under pressure to give a definative statement or else the engineers with the dissenting view points decided they weren't sure enough of their positions to take a stand.

        But why should any engineer have to be sure about their analysis? They are dealing with a limited amount of data with a large number of unknown variables. So perhaps the minority engineers figured that they were just really making an educated guess, but then so were the majority engineers. What basis would they have for disagreement, so if a conclusion was asked for then it makes sense to go with the conclusions of the majority, very simple and in most cases most of the time it will give you a good result. But they had the resources and time to continue to analyze this and it would make sense to continue to do so if a real worst case scenario had emerged.

        Seems to be that this type of bad decision making
        is what needs to be addressed at NASA. Yes, the foam needs to be fixed, but it wasn't like the O-Ring problem in the Challenger accident when the weather conditions caused a catastrophic failure of the seal. Rather this was a catastrophe that unfolded over many years and culminated when a NASA spokesman told reporters that the falling foam was not a problem.

        This foam accident had happened before and could have been fixed, before the columbia even flew. But like the drunk that decides that they have driven home before without a problem so why should tonight be any different, they largely decided to rely upon experience. But this is not the type of problem where experience can be used. This wasn't even really engineering, they were being asked to solve a mystery.

        Analysis by consensus with a single conclusion was a bad idea in this situation. If you are going to take a vote and then report the result as a conclusion, then that is a fundamental mistake. Like asking a roomful of people if God really exists. The majority might say yes or no, but won't you still want a few people praying just in case.

        If the initial analysis of the foam strike had included the minority opinions then NASA management could have directed more resources towards the analysis, they would have gotten the military to take a picture of the wing and then perhaps had the astronauts do and EVA to take a look and then perhaps launched the Discovery for a rescue mission and this could have had a very happy ending. If the initial analysis had included any indication that the conclusions were not certain, then it seems likely and obvious that these additional steps would have been taken. In fact the military had already been put on standby to take some pictures of the affected area, but it wasn't to be.

        So, it isn't clear to me if the engineers were truly at fault here or if it was the management process that was in place. Certainly engineers could have expressed certainty in their concerns, but why express certainty when there is none? Seems to me the problem here was that the engineers were asked to reach a conclusion and they did. They clearly did not have enough evidence to be certain of what effect the hit would have on the shuttle. Unless another timeline comes to light, I have to conclude that the faulty analysis came from the management of the engineering group or from the nature of the directive that that group received. This is what should be addressed, anomali
    • Re:Basic Physics (Score:2, Informative)

      by tomstdenis ( 446163 )
      Birds take down planes because they kill the engines. A bird hitting a 747 wing will just be obliterated.

      Otherwise flying through heavy snow/rain would down every aircraft on earth.

      Tom
  • by gpinzone ( 531794 ) on Thursday June 05, 2003 @08:32AM (#6123053) Homepage Journal
    Everything flying around in space is potrentially dangerous. A fleck of paint hit one of the space shuttle's windows once and caused a surprising about of damage. Based on momentum, it was the equivalent of a bowling ball hitting the shuttle at 60 MPH. Yeah, that's definately dangerous.
  • by Mattygfunk1 ( 596840 ) on Thursday June 05, 2003 @08:32AM (#6123055)
    and privately predicted that the foam would bounce off harmlessly, like a Nerf ball.

    It is pretty obvious that these guys are geeks yes?

    __
    Cheap reseller hosting [cheap-web-...ing.com.au] Action figures dragon [mibglobal.com.au]

  • Bad picture? (Score:3, Interesting)

    by rwiedower ( 572254 ) on Thursday June 05, 2003 @08:32AM (#6123059) Homepage
    In this frame from film of a test, foam is seen after it hit a mock-up space shuttle wing at great speed and shatters, leaving V-shaped tracks.

    Did they print the wrong picture? The article implies a great deal of damage but all I can see in the picture is the foam object getting destroyed. The wing itself looks completely fine.

  • by BenjyD ( 316700 ) on Thursday June 05, 2003 @08:36AM (#6123086)
    "That's when it came home to me what 1/2mv2 means"

    This guy is a rocket scientist? I guess that's one stereotype debunked.
    • by spotteddog ( 234814 ) on Thursday June 05, 2003 @08:59AM (#6123280) Journal
      The article says he is the Director of NASA Ames research center, not that he *is* a rocket scientist. He is not a rocket scientist. His bio (http://www.arc.nasa.gov/about_ames/hubbard.html) from NASA shows him to be a long time administrator, with his original scientific background in radiation detection materials and devices.

      So will people *PLEASE* quit insulting rocket scientists.
  • Relative velocity? (Score:5, Interesting)

    by dschuetz ( 10924 ) * <david&dasnet,org> on Thursday June 05, 2003 @08:36AM (#6123089)
    I've been wondering this from the beginning of the foam investigations and tests...

    They've talked about firing foam samples at wing mockups at hundreds/thousands of miles an hour, 'cause (I think) the Shuttle was flying at that speed when it was hit. But wasn't the foam also flying at that speed? Shouldn't the actual velocity of the foam hitting the wing edge be fairly minimal?

    Or are they assuming that the wind drag on the foam chunk would reduce its absoute speed significantly, thus increasing the relative speed with which it hit the wing?

    In other words, did the foam fall off and drop, low speed, into the wing, or did the foam flake off and stop dead in the air, then the shuttle ran into it at a huge velocity?
    • The instant the foam was no longer in contact with the rest of the shuttle, it would no longer have rocket thrust acting on it, only drag from the air, so it would have slowed down quite quickly.

    • by mr_z_beeblebrox ( 591077 ) on Thursday June 05, 2003 @08:46AM (#6123178) Journal
      They've talked about firing foam samples at wing mockups at hundreds/thousands of miles an hour, 'cause (I think) the Shuttle was flying at that speed when it was hit. But wasn't the foam also flying at that speed? Shouldn't the actual velocity of the foam hitting the wing edge be fairly minimal?

      You are probably somewhat right, the velocity of impact is something like the speed of the shuttles ascent - speed of the foams ascent. However to maintain a 500 MPH ascent requires a considerable amount of constant energy. The foam probably decelerated much quicker than you are thinking.
      • by djward ( 251728 )
        Perhaps this is why the foam didn't do much damage before - due to circumstances it never slowed down enough relative to the shuttle to do much damage. But this time, the position or orientation of the foam was right for it to be going way slower than the shuttle when it hit.
  • by MtViewGuy ( 197597 ) on Thursday June 05, 2003 @08:36AM (#6123090)
    I think when people talk about the foam insulation hitting the leading edge of the left wing of Columbia during the launch phase, they have to consider the following:

    1) When the insulation piece fell off it was essentially encased in solid ice, which is a pretty hard material to start with.

    2) At the time the insulation fell off, the space shuttle was travelling a couple thousand miles per hour already. That could (in theory) add to the impact force on the wing.

    NASA should have tested the insulation foam encased in ice fired at physical simulation of the shuttle leading edge, in my opinion.
    • by kinnell ( 607819 ) on Thursday June 05, 2003 @08:46AM (#6123184)
      When the insulation piece fell off it was essentially encased in solid ice, which is a pretty hard material to start with.

      How much ice exactly? There's no way of knowing. They do know how much foam fell off. If they test using just foam, they know the minimum amount of damage done for sure. If they add a guestimated amount of ice, they haven't proven anything.

      At the time the insulation fell off, the space shuttle was travelling a couple thousand miles per hour already. That could (in theory) add to the impact force on the wing.

      It's irrelevant how fast the shuttle was travelling. Only the speed of the foam relative to the wing matters (i.e. when bloan by a thousand mph wind). Presumably they measured this from the video they had.

    • No sir, The shuttle was not travelling that fast.The article clearly says 531 miles per hour.It was just picking up speed.
      Also the Ice thing is just a possibility, Only if air (which contains water vapour) gets in between the foam and whatever cool part it was covering will ice form.If that was the case, Nasa has bigger problems to worry about.
      • Actually, the article clearly says they tested a piece of foam traveling 531 miles per hour. So that's the speed they expected the foam to have accelerated up to by the time it hit, but not necessarily the speed of the air going by.
      • Kind sir, the shuttle was probably doing 500 mph within the first 15 seconds after liftoff. Since the foam impact occured some 80-90 seconds after liftoff, it should be easy to infer that the shuttle's speed was in the 1000's of mph.

        The exact values can be found in public record if you choose to look

        The foam was moving 500 mph relative to the wing

  • Intuition (Score:4, Insightful)

    by aeinome ( 672135 ) on Thursday June 05, 2003 @08:37AM (#6123095) Journal
    "people's intuitive sense of physics is sometimes way off."

    No kidding. How could they think a piece of foam shot at over 500 mph would bounce off harmlessly? Nearly everyone knows a penny dropped off the Empire State Building can kill someone- this foam (which is heavier, and is going faster than the penny would be going) would most certainly do damage.
    • by In-gin-eer ( 643894 ) on Thursday June 05, 2003 @08:46AM (#6123181)
      I don't have the numbers right here, and I'm too hungover to crunch them out, but I remember a few years back being told by a professor that a penny can't kill someone. It's too light, and the air resistance creates a terminal velocity that prevents it from becoming all that dangerous.

      And the empire state building is wedge shaped, with ledges ever couple of stories. There's no way for a penny to even make it to the ground.

      Also, it's not the fact that the foam was going 500 mph hour, it's the fact that the shuttle was.
    • by MacAndrew ( 463832 ) on Thursday June 05, 2003 @09:53AM (#6123821) Homepage
      You're right on the falling penny issue, at least according to this empirical report [urbanlegends.com]. Isn't it nice when someone actually tries the experiment rather than accepting the conventional wisdom?

      It's intuitively correct, but I should warn that the physics of sleeker objects like cellphones are quite different, judging from the one dropped on me while descending a staircase last Memorial Day. Fortunately for me it was a glancing blow -- the phone shattered after deflecting from my head. Apparently a cellphone in freefall is not accompanied by an apology, but I took satisfaction enough in the destruction of the phone. :)
  • Astounding... (Score:5, Insightful)

    by kinnell ( 607819 ) on Thursday June 05, 2003 @08:37AM (#6123096)
    ...that they've only just performed this experiment. They claimed earlier that foam falling off the fuel tank not extraordinary, and hadn't been a problem in the past. You'd think with the risks involved it might be worth checking out - just in case. The whole point of engineering is that we don't rely on intuition.
    • > ...that they've only just performed this experiment.

      You must not work for the government. EVERYTHING operates at a glacial speed.

      It takes a month of meetings to decide on a course of action, two months to do any purchasing required, then another month to assemble the stuff that was bought.. then actually do the job that the meetings decided they should do.

      You may think I'm kidding, but I'm not. :p This test is actually right on schedule.

      In fact unless I've already lost track of the passage of time
  • by Pastey ( 577467 ) on Thursday June 05, 2003 @08:37AM (#6123100)
    ...than Columbia's as well.

    From the article:

    The next round of tests in Texas could add weight to the growing consensus about the cause of the accident. Last week's tests used wing panels from the Enterprise, a test vehicle that never flew in space. That craft's leading edge panels were made from fiberglass because the Enterprise never had to face the heat of re-entry.

    Foam testing will resume on Thursday with the first effort to fire a chunk of foam at the actual material used on the leading edge of the shuttle's wing. The material, reinforced carbon-carbon taken from the shuttle Discovery, is substantially weaker and less flexible than fiberglass.



    A lesson in kinetics indeed. Perhaps it was a micro-meteorite or junk, but based on this data I'd say they've solved it.
  • I suspect that this is just gamesmanship from NASA and G. Scott Hubbard seems to be pretty good at it.
  • are you kidding... (Score:3, Insightful)

    by suavivity ( 672245 ) on Thursday June 05, 2003 @08:40AM (#6123121)
    "That's when it came home to me what 1/2mv2 means...the force was equivalent to catching a basketball thrown at 500 miles per hour."

    is he serious?? performing a 5 second equation before telling the shuttle to come back could have predicted and prevented this tragedy. i'm glad it's hitting home for him now...too bad he completley forgot his rudimentary physics a few months ago. this is just another in a long line of examples of NASA engineers not being up to par with basic math. (what...yards != meters???)
  • Scary Stuff (Score:5, Interesting)

    by OrangeGoo ( 678478 ) on Thursday June 05, 2003 @08:40AM (#6123123)
    It's frightening that such a light-weight piece of foam can doom a fantastically complex and brilliant piece of machinery like the shuttle, not to mention the crew on board who are far more complex and brilliant - and the loss of whom is so much more painful. But it's not really a surprise. I mean, if a penny can kill - and it certainly can - then so can a big block of foam, even if it doesn't weigh much.

    Unfortunately, dangers such as these are just a part of space flight. It's never going to go away: as someone else posted earlier, birds can bring down planes and that's a mature technology. If space flight ever becomes routine, it will still be filled with dangers - the question is whether or not people are willing to take the risk. From a scientific perspective, we're very, very lucky that so many astronauts are willing to take it to advance our understanding of the world and the universe.

    Still, it's really hard to see that shuttle crew lost to a piece of foam. Or a piece of rubber (Challenger). It strikes me as odd that on something as monstrously complicated as the shuttle, the only two complete failures were due to relatively simple components. It also strikes me as a major accomplishment. Anyway...
  • Birds? (Score:3, Interesting)

    by cperciva ( 102828 ) on Thursday June 05, 2003 @08:40AM (#6123125) Homepage
    If a chunk of foam can cause this much damage, what happens if a bird gets in the way?

    I know they test-fire birds at the fuselage, but if a bird hits the wing (or rather, if the wing hits a bird) it could cause problems.

    They can find ways to ensure that foam doesn't come loose like this in the future, but I don't think they can eliminate the possibility of overflying birds.
    • By the time the shuttle is moving at velocities making the situation dangerous, it would be at a higher altitude than any birds would be able to fly.

    • I imagine that the aerodynamics of the fusalage prevent this problem, similar to bugs being channeled up and over your car if you are traveling at the correct velocity rather than smacking into your windshield.
  • Oh no! (Score:3, Funny)

    by Lord_Slepnir ( 585350 ) on Thursday June 05, 2003 @08:41AM (#6123130) Journal
    I didn't know foam could do that much dammage. I should be more careful before I go to Belegarth Practice [foamfighting.org] this weekend.
  • "He invoked the physics equation that describes the amount of kinetic energy in a moving object, saying, "That's when it came home to me what 1/2mv2 means." The simple equation says that kinetic energy is one-half times an object's mass times the object's velocity squared, so that even something very light can carry a great deal of force if it is moving fast enough. In fact, he said, the force was equivalent to catching a basketball thrown at 500 miles per hour."

    If it's such a simple formula and the facts
  • by bigfatlamer ( 149907 ) on Thursday June 05, 2003 @08:44AM (#6123155)
    The most frightening part of this whole story is that the people expressing shock (SHOCK!) at the amount of damage a piece of foam can do at 500+ MPH are actual Rocket Scientists. Is a basic grasp of physics not required for an advanced degree in Aerospace Engineering?

    The second most frightening part of the story is that these tests were performed on a mock-up wing taken from the Enterprise (which has never flown) and is made out of fiberglass, a stronger (but much more heat labile) material than the carbon-carbon stuff the leading edge of the actual wing was made from. I wonder how nasty the results will be once they use the real material that failed.

    BFL
    • by cybercuzco ( 100904 ) on Thursday June 05, 2003 @09:42AM (#6123719) Homepage Journal
      There is a difference between knowing something, and knowing when to apply it. There is a further difference when there is a distinct incentive to minimize risk and danger. People are covering their asses now. How would people react if one of the engineers or managers said "Im not really surprised it caused that much damage, I knew all along, its just a simple equation, e=1/2mv^2" Well that opens him up for liability, if he knew all along, why the heck didnt he say something while columbia was still in space? Im sure people knew, but there was nothing that could be done, so they just had to cross their fingers, and now they have to cover their asses.
    • The guy expressing 'shock', is an administrator. He is the chief at NASA Ames, where I work, and part of his job is to 'interface' with the public. That sometimes (often?) leads to statements that would make a scientifically minded person cringe. I expect these comments will be widely reported, and widley condemned as the NASA scientists being incompetant...
    • It may have been shock just not at the damage that such a piece of foam could cause, but also at the fact that it was travelling at 500mph. What happens if you shoot a marble at 60mph at the windshield of a car - it breaks or at least cracks. Now reach out your window and drop a marble on your windshield while travelling at 60mph - nothing happens. This is of course because the marble was travelling at zero velocity compared to your vehicle. So was the foam that hit the space shuttle - at least in the m
  • Amazing these people. Don't we all remember the ol' mv^2 equation? You shoot almost anything with sufficient force it's going to cause damage. To make matters worse I guess the real problem is that the foam gets even harder due to the cold that it's insulating (go figure).

    Next we'll have terrorists near the shuttle launch with slingshots... :-}
  • by fname ( 199759 ) on Thursday June 05, 2003 @08:45AM (#6123164) Journal
    Well, there are a couple things at play here:

    1) Materials are stronger at higher strain rates; essentially, the foam can probably remain elastic to much higher stresses when it is being deformed quickly, in a case such as this. To know more, you would want to do a series of high-strain rate tests on the foam to measure it's basic properties. In hindsight, choosing a foam with poor high-strain-rate performance should have been a requirement.

    2) The piece of foam they fired was so big that it probably acted as a constriant; essentially, a piece of foam being confined laaterally will have greater apparent strength than one that is not. When a very small piece of foam is fired, this effect would not be present. Scale is important, beyond just increased mass causing increased damage.

    It seems so obvious now, but I hadn't thought of these things before. Ideally, NASA would've conducted tests long ago with many sizes of foam hitting many parts of the shuttle, instead of abandoning the tests after seemingly benign results, in addition to basic experiments-- tests of the confined and unconfined foam.
  • by Anonymous Coward on Thursday June 05, 2003 @08:46AM (#6123179)
    First there's L. Ron Hubbard, now G. Scott Hubbard? Maybe the problem is that they were using Scientology for the first mid-mission damage assessment instead of science? It's all becoming clear now...
  • by TheViffer ( 128272 ) on Thursday June 05, 2003 @08:53AM (#6123230)
    can jam pieces of straw into telephone poles and brick one would say "ummm ... Duh".

    And even then an F6 on the Fujita scale which is completely inconceivable (if the F5 is the finger of God, this is the "2-stroke 250cc dirt bike of God") would have wind speeds of 319+ MPH

    • by crawling_chaos ( 23007 ) on Thursday June 05, 2003 @11:18AM (#6124678) Homepage
      In fact, the Apollo command modules had something called the Boost Protective Cover over them during liftoff to prevent damage to the exterior of the spacecraft. It was carried away with the escape rocket when that was jettisoned.

      And that was merely to protect the weaker heat shielding on the conical part of the spacecraft. The blunt end heat shield was protected by the Service Module until shortly before re-entry. The ice generating fuel tanks were also below the space craft, instead of partially above it. One of the problems with the Shuttle design is that much of the heat shielding is exposed during lifoff. I suppose some variation of the BPC could have been designed for the leading edges of the wings, but there certainly would have been a weight penalty, and the Shuttle is a heavy bird to begin with.

      This is a problem that is going to have to be solved if a production re-usable spacecraft is ever to happen. We might not be at the stage of materials science to do it yet, though.

  • by AlpineR ( 32307 ) <wagnerr@umich.edu> on Thursday June 05, 2003 @08:53AM (#6123233) Homepage
    While the Columbia was in orbit, the Boeing engineers made a presentation to NASA about their prior tests of how much damage the foam might do. Edward Tufte [edwardtufte.com] has analyzed the slides [edwardtufte.com] and illustrated how not to present scientfic data. Basically, the actual foam chunk was far larger than anything they had used in testing. But poor wording and misleading statements obscured that important point.

    Tufte also examined the Challenger evidence in his excellent book Visual Explanations [amazon.com].

    AlpineR

  • Anybody who has seen a piece of straw pushed through a tree or other tornado damage wouldn't be a bit surprised by the damage a bit of foam travelling at 500mph would do. I'm surprised the engineers could have missed this. They should know this kind of thing cold.
  • by zdburke ( 304337 ) on Thursday June 05, 2003 @08:58AM (#6123268) Homepage

    The videos are here [streamos.com] (where the panel visibly ripples after the impact) and here [streamos.com].

    The accompanying slide presentation [caib.us] has the details: the 1.7 pound foam block was fired at 531 mph and, where it struck a T-seal between two panels, displaced them and caused a 4/10 inch gap. This fake wing was made of fiberglass, but given the results, a test with actual shuttle wing material from the Space Shuttle Discovery is planned for today.

    Here are some of the headlines [google.com] from news.google.com [google.com]:
    Shuttle Wing Under Gun [newsday.com]
    Investigator Amazed by Shuttle Foam Force [yahoo.com]
    Foam theory faces pivotal test [chron.com]
    Tests Show Foam Causing Wing of Shuttle to Deform [washingtonpost.com]
    Foam chunk was shuttle's undoing, tests indicate [globeandmail.com]

  • Why are all the reports I've read on this been so vague about the experimental setup? they all say "foam shot at wing section... did we mention the wing section was made from fiberglass?"

    From how far away was it shot? How cold was the wing section? What was the ambient air pressure?

    What was the foam shot out of??!?
  • by Anonymous Coward on Thursday June 05, 2003 @08:58AM (#6123271)
    I mean, tornados can punch 2x4s through concrete walls, and embed a piece of straw into a tree, and their winds maybe are 300 mph tops.


    So a 1.7lb chunk of foam going 500 mph would do SERIOUS damage. Come on! I mean, what kind of physicists are they hiring that can't wrap their brains around this?


    500mph = 804,672 m/h = 224 m/s

    1.7lb = 0.77kg

    from 1/2mv^2, we get...

    0.5*0.77kg*(224 m/s)^2 = 19,000 joules of energy!


    From a website on the power of explosives...

    TNT releases 2.72x10^6 J/kg

    So...

    g of TNT = (19,000 J/ (2.72x10^6 J/kg) )*1000g/kg = 7g ~ 0.25 Oz

    The size of a large blasting cap.


    Now, if you asked Nasa if setting off a blasting cap on the shuttle wing would be good or bad, well, I'd think they'd give you an incredulous look and call the FBI on you for being a terrorist and asking suspicious questions.


    This back of the envelop calculation MAY be off somewhat. But any engineer who sat down and said "Does this make sense" could have done it on an envelop as a sanity check.


    Now, knowing that foam hitting the wing is like setting off a blasting cap on it, perhaps people will realize the dangers of light things traveling very fast...


    Hmmm, I wonder how much energy a feather traveling at 0.5C would release...

    • The math isn't quite that simple... in that, how do you know how fast the foam would be traveling when it hit the wing? NASA already did the calculations for you: 531mph. Was that calculation a back-of-the-napkin calculation too? Would NASA administrators automatically believe you that it was going 531 mph?

  • What bothers me is the 500 miles per hour number. It's irrelevant how fast the foam was moving relative to the ground, only how fast it was going relative to the shuttle wing. And since this liftoff was very non-realativistic, we can use classical kinematics:

    This foam was attached to the tank at lift-off, right? That means it was going the same speed as the shuttle at that instant it broke off. THAT means that RELATIVE TO THE SHUTTLE, it accelerated from zero to 500 mph (AGAIN, ELATIVE TO THE SHUTTLE) in the space of 200 ft or so. Well, using the kinematics equation:

    Vf^2 - Vi^2 = 2ad

    with:
    d = (worst case for most acceleration) = shuttle length = 200 ft,
    Vi=0
    Vf = 500 mph = 733 ft/sec

    gives

    acceleration = a = (Vf^2 - Vi^2)/2d = 733^2/(.0379 * 2)= 7088245 ft/sec^2 = 220000 times the acceleration due to gravity!

    Check my numbers, please, but that seems a little high to be caused by braking due to air resistance.

    • The extreme acceleration is because the force due to the air is large while the mass of the foam is small. a = F / m can then produce a huge number.

      But regardless, I believe the 500 mph was measured by looking at how far the foam moved between frames of video, relative to the shuttle.
      I don't think it was calculated from an acceleration.

    • OK, no need to check your numbers.

      But gravity is not the only force involved. The shuttle was moving up at 1000 miles an hour.... through the air and the wind. When the foam broke away, it immediately became subject to wind resistance, and slowed down due to wind. A 2 pound piece of foam in 1000 mile an hour wind can change velocity quite a lot in 200 feet. It was able to slow down (relative to the ground/wind) by 500 miles an hour due strictly to wind resistance.

      The math is left as an excercise for the v

    • by aardvarkjoe ( 156801 ) on Thursday June 05, 2003 @09:41AM (#6123710)
      Almost. But you converted your 200 feet into miles -- which you weren't supposed to do. Using the correct numbers, you get (733^2)/400 = 1344 = about 42 g's. Since air resistance is proportional to a (very large) velocity, that doesn't seem too farfetched.
    • Vf^2 - Vi^2 = 2ad

      This formula assumes constant deceleration. However, aerodynamic drag (and hence deceleration) is proportional to the square of the velocity.

  • But Mr. Hubbard said the experiment showed that "people's intuitive sense of physics is sometimes way off."

    Keep this in mind next time you hear about a "Duh" experiment. Scientists routinely test even the most "obvious" of assertions, because every so often those "obvious assertions" are actually wrong.

  • Don't be morbid (Score:2, Insightful)

    by Hao Wu ( 652581 )
    I can't stand when the media sells disaster, cable programs like "What Went Wrong?"....

    Leave the engineering issues to engineers and scientists. The general public doesn't give a rat's ass about kinetic energy or materials science, they just use it as an excuse to re-live the tragedy over and over.
  • Considering how much damage something as small as a paint fleck can do [nasa.gov], at high speeds, a 1.5 pound chunk of anything can be dangerous.

  • by jaredcoleman ( 616268 ) on Thursday June 05, 2003 @09:42AM (#6123724)

    This illustrates why it may be a good idea to put some money into research of an alternative to the shuttle program. The shuttle program will always face dangers of this type, considering the speeds/forces involved in getting the shuttle into orbit.

    Perhaps a program where a spacecraft could actually take off like an airplane and be piloted out of the atmosphere. Even if a large burst of propulsion was needed to get it out of the atmosphere: it would be pulling less G's since it would already be moving with good speed, it would have to do so for less time, and there possibly wouldn't be external systems needed to do it (booster rocket and foam...).

    If the official consensus ends up being that the foam caused this, perhaps it will be an impetus for change.

  • Foam misconception (Score:5, Interesting)

    by confused one ( 671304 ) on Thursday June 05, 2003 @09:49AM (#6123777)
    I keep seeing people refer to this stuff in comparison to a nerf ball. This is way off !!!

    The tank is coated in a hard foam similar to the polyurethane foam used in insulation.

    Do a little experiment yourself here (warning: not for little children : ) Go to the hardware store and find a can of "Great Stuff" foam insulation spray. It's used to fill the holes in walls around pipes.

    Now, lay out a plastic trash bag, and empty the entire can onto the bag -- (warning: the stuff expands as it hardens; so, start in the middle of the bag).

    Once it hardens, take a look at the result. This is similar stuff, not quite as nice as what they use on the shuttle of course... Also, keep in mind that an entire can of "Good Stuff" is only 12oz. (3/4 lb). You'd need over two cans of the stuff to make a piece the size they're talking about.

    Think about that hitting you doing 500 mph...

  • by earthforce_1 ( 454968 ) <earthforce_1@y a h oo.com> on Thursday June 05, 2003 @10:02AM (#6123894) Journal

    These stories of ice covered foam remind me of something...

    In one of the NRC labs in Ottawa, they have a "chicken gun" that fires broiler chickens at high velocity into mock ups of aircraft windshields. It is probably an urban legend, but I heard a story that some British engineers decided to duplicate the experiment, and were horrified to find that the chicken smashed a hole clear through the windshield mockup and buried itself in the far wall. They emailed their Canadian colleages to ask what they were doing wrong. The reply was simple: "thaw the chickens first."

    But seriously, as the velocities increase, so does the danger. I once saw a picture of the windshield on another orbiter that had been struck by a tiny fleck of paint from an old booster. It looked like it had been struck with a bullet, and had the paint fleck been slightly larger, NASA would have had yet another catastrophic end to a shuttle mission.

    If we ever develop a really good propulsion system that can approach light speed, we had better invent deflector shields along with it. As you hit relativisitic speeds, anything you collide with releases energy proportional to an equivalent sized hydrogen bomb. Even molecules become dangerous, and a dust speck would blow a good sized hole in your spacecraft.

    • by reverseengineer ( 580922 ) on Thursday June 05, 2003 @11:00AM (#6124486)
      Yeah, the "frozen chicken in the gun" is an urban legend. [snopes.com] As the article notes, such devices do exist for the purpose of testing objects for bird impact (but many now use pigeons of the clay species), but the frozen bird goof is not known to have ever happened (other than intentional tests using frozen birds).

      What's really funny (and what provides an additional clue that this is an urban legend that's been around the block a few times) is that in most versions of the legend, it is a group of American engineers who have to clue in their foreign counterparts (their nationality varies too) that they have to thaw the birds first. If there's one universal in comedy, though, it's making fun of foreigners.

  • by somethingwicked ( 260651 ) on Thursday June 05, 2003 @10:07AM (#6123949)
    First, RTFA...

    "In fact, he said, the force was equivalent to catching a basketball thrown at 500 miles per hour."

    THEN

    although the experiment "moves us a lot closer to saying that foam can do this kind of damage," it did not rule out other possible causes of the hole in the wing, including small meteorites and debris in space.


    What is it about this being a peice of foam that they still can't cop to this being most likely.

    If I saw you throw a basketball at my car at 500mph, I would likely stop looking for the "real" cause of the dent!

    Even after the experiment and the basic lesson in physics, they still won't say "Yeah, we are keeping our minds open to any new evidence, but right now it appears that this foam strike was the a major factor in the accident."

    THERE IS NOTHING WRONG WITH SAYING "Yes, we think this is what caused the damage" If it was instead the basketball that indeed hit the shuttle, the debate about what caused the damage would be wrapping up.

    I say major factor, becuase I personally have theorized on /. before about the idea of ALL factors involved.

    Below is the text of my former post on this idea-

    'Under the conditions of a normal return to earth, the shuttle flies on autopilot until it is traveling more slowly than the speed of sound. But pilots train to take the shuttle all the way down in case the autopilot malfunctions, and so it is possible one of the pilots was trying to take control of the yawing craft in its final moments. 'It is relatively easy for the autopilot to be turned off by accident, which in fact happened just minutes before the problems with the Columbia started to become apparent. In the recovered segment of flight deck video of the waning minutes of the flight released by NASA, Colonel Husband is heard to exclaim, "Oh, shoot," and to tell mission control that "we bumped the stick earlier," briefly disengaging the autopilot. He quickly and calmly corrected the error'
    What this all leads me to is this, and I have not seen this suggested in anything I have read as an important concern: Is it possible that this accidental disengaging of the autopilot CONTRIBUTED to the loss of the Shuttle? Although the pilots are trained to fly the Shuttle without the Autopilot, if they were unaware that it was turned off then the "minute" adjustments that either one would make would be missed. All accounts I have seen suggest that the slightest details on the approach make HUGE differences in the results. Add to this the fact that it has been reported that the Autopilot, when on, was acting to correct the flight path anomalies caused by the damage outside. If the autopilot is off, then what other consequences were being experienced?
    Is it possible that this with the likely outside damage and other factors may have COMBINED have caused the loss of the Shuttle where any issue ALONE would have not? With all the speculation I have seen in the media, I am not sure this is any less of a possibility...
    BTW, I personally am not trying to lay blame on the astronauts themselves. Much like a Cruise Control that starts to mysteriously disengage on a vehicle, I would not be surprised if the Autopilot may have "sensed" a disengage as simple as moving the stick, and the pilots assumed that one of them must have done it."

  • by Crusty Oldman ( 249835 ) on Thursday June 05, 2003 @10:10AM (#6123982)
    From day one, they have danced around the subject of ice. They just won't talk about it.

    The Shuttle's main tank is a huge cryogenic storage cylinder. It is cold, very cold. So cold that they have to insulate it. So cold that atmospheric air will form a sheet of ice on its outsides. So cold that ice formation is monitored before launch. Why won't they talk about this?

    The leading portion of an aircraft body and wing is where ice will accumulate in flight. It can collect in amounts large enough to make the aircraft unaerodynamic. Amounts large enough to fall off in chunks. Why won't they talk about this?

    The material seen impacting the Shuttle wing has been described as "grayish-white". Ice just happens to be this same color. What color was the insulation? Was it grayish-white too? I doubt it! If the insulation were the same color, how could they visually check against ice formation before launch?
  • by sjbe ( 173966 ) on Thursday June 05, 2003 @10:26AM (#6124153)
    Why does the old joke about "which is heavier, a pound of feathers or a pound of lead?" keep coming to mind?

    Folks, a small weight moving fast packs a lot of punch. Even foam/feathers/pillows.

  • Ice? (Score:3, Insightful)

    by hughk ( 248126 ) on Thursday June 05, 2003 @11:01AM (#6124501) Journal
    From what I remember that after fueling and before the shuttle starts moving, there tends to be condensation forming on the exterior of the external tank (even with the foam insulation. The condensation tends to freeze.

    I don't know how fast the air friction melts this, but wouldn't foam laden with ice be even worse?

  • by geekee ( 591277 ) on Thursday June 05, 2003 @01:12PM (#6125610)
    The insulating foam for the space shuttle that broke off and possibly destroyed the shuttle was a new formula since 1997 that has been problematic since it replaced a freon based foam. Although the freon-based foam worked better, the new foam was used instead rather than getting an exemption. So, if the foam is the root cause, it appears political correctness was more of a concern than using the best material for the job, possibly costing the lives in the process. Here's an article [foxnews.com] on the subject
  • by JoeSilva ( 215173 ) on Thursday June 05, 2003 @01:45PM (#6125861)

    It's looking more and more like there was a management decision to accept foam impacts despite the engineers of the shuttle specifying that nothing should impact the shuttle.

    Previous reports indicated NASA management argued that the impacts were OK since nothing bad happend from past impacts,and because it was "just foam". Some of the same articles stated that the engineering design docs stated no impacts were acceptable.

    The challenger disaster was for sure due to managers deciding to launch against the strong advice of the engineers not to launch.

    This current article's quote of the NASA Ames person (who has been in management for awhile now as someone has already pointed out) surely is suggestive of the problem. It indicates his surprise that the physics don't match his inuitive expectation. Maybe that's a root of the problem. People with some science background in a non-relevent field who move on to a management role are relying on their own intuition over that of those that are doing the actual engineering in the relevent field.

    For sure if they were going to accept the impacts then they had a responsibility to put the resources into experts carefully analyzing what the outcome would be for all the possible impact area's and times. That would allow a scientifically informed decision.

    Instead there was an intuitivly informed decision.

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