Space Shuttle Challenger – assembled for launch along with the
ET and two
SRBs – atop a
crawler-transporter en route to the launch pad about one month before the disaster The
Space Shuttle was a partially reusable spacecraft operated by the US
National Aeronautics and Space Administration (NASA). It
flew for the first time in April 1981, and was used to conduct in-orbit research, and deploy commercial, military, and scientific payloads. At launch, it consisted of the
orbiter, which contained the
crew and payload, the
external tank (ET), and the two
solid rocket boosters (SRBs). The orbiter was a reusable, winged vehicle that launched vertically and landed as a glider. Five orbiters were built during the
Space Shuttle program.
Challenger (OV-099) was the second orbiter constructed after its conversion from a structural
test article. The orbiter contained the crew compartment, where the crew predominantly lived and worked throughout a mission. Three
Space Shuttle main engines (SSMEs) were mounted at the aft end of the orbiter and provided thrust during launch. Once in space, the crew maneuvered using the two smaller, aft-mounted
Orbital Maneuvering System (OMS) engines. When it launched, the orbiter was connected to the
ET, which held the fuel for the SSMEs. The ET consisted of a larger tank for liquid hydrogen (LH2) and a smaller tank for liquid oxygen (LOX), both of which were required for the SSMEs to operate. After its fuel had been expended, the ET separated from the orbiter and reentered the atmosphere, where it would break apart during reentry and its pieces would land in the
Indian or
Pacific Ocean. Two solid rocket boosters (SRBs), built by
Morton Thiokol at the time of the disaster, provided the majority of thrust at liftoff. They were connected to the external tank, and burned for the first two minutes of flight. The SRBs separated from the orbiter once they had expended their fuel and fell into the
Atlantic Ocean under a parachute. NASA retrieval teams recovered the SRBs and returned them to the
Kennedy Space Center (KSC), where they were disassembled and their components were reused on future flights. Each SRB was constructed in four main sections at the factory in Utah and transported to KSC, then assembled in the
Vehicle Assembly Building at KSC with three
tang-and-clevis field joints, each joint consisting of a tang from the upper segment fitting into the clevis of the lower segment. Each field joint was sealed with two diameter
Viton-rubber O-rings around the circumference of the SRB and had a cross-section diameter of . The O-rings were required to contain the hot, high-pressure gases produced by the burning solid propellant and allowed for the SRBs to be rated for crewed missions. The two O-rings were configured to create a double bore seal, and the gap between segments was filled with putty. When the motor was running, this configuration was designed to compress air in the gap against the upper O-ring, pressing it against the sealing surfaces of its seat. On the SRB Critical Items List, the O-rings were listed as Criticality 1R, which indicated that an O-ring failure could result in the destruction of the vehicle and loss of life, and that it was considered a redundant system due to the secondary O-ring.
O-ring concerns , along its circumference. The bottom end of the top segment extends to form a tang that fits snugly into the clevis of the bottom segment. Two parallel grooves near the top of the clevis inner branch hold ~20 foot (6 meter) diameter O-rings that seal the gap between the tang and the clevis, keeping hot gases out of the gap. |alt=Diagram from the Rogers Commission depicting a cross-section of the solid rocket booster field joint Evaluations of the proposed SRB design in the early 1970s and field joint testing showed that the wide tolerances between the mated parts allowed the O-rings to be
extruded from their seats rather than compressed. This extrusion was judged to be acceptable by NASA and Morton Thiokol despite concerns of NASA's engineers. A 1977 test showed that up to of joint rotation occurred during the simulated internal pressure of a launch. Joint rotation, which occurred when the tang and clevis bent away from each other, reduced the pressure on the O-rings, which weakened their seals and made it possible for combustion gases to erode the O-rings. NASA engineers suggested that the field joints should be redesigned to include
shims around the O-rings, but they received no response. In 1980, the NASA Verification/Certification Committee requested further tests on joint integrity to include testing in the temperature range of and with only a single O-ring installed. The NASA program managers decided that their current level of testing was sufficient and further testing was not required. In December1982, the Critical Items List was updated to indicate that the secondary O-ring could not provide a backup to the primary O-ring, as it would not necessarily form a seal in the event of joint rotation. The O-rings were redesignated as Criticality1, removing the "R" to indicate it was no longer considered a redundant system. The first occurrence of in-flight O-ring erosion occurred on the right SRB on in November1981. In August1984, a post-flight inspection of the left SRB on revealed that soot had blown past the primary O-ring and was found in between the O-rings. Although there was no damage to the secondary O-ring, this indicated that the primary O-ring was not creating a reliable seal and was allowing hot gas to pass. The amount of O-ring erosion was insufficient to prevent the O-ring from sealing, and investigators concluded that the soot between the O-rings resulted from non-uniform pressure at the time of ignition. The January1985 launch of was the coldest Space Shuttle launch to date. The air temperature was at the time of launch, and the calculated O-ring temperature was . Post-flight analysis revealed erosion in primary O-rings in both SRBs. Morton Thiokol engineers determined that the cold temperatures caused a loss of flexibility in the O-rings that decreased their ability to seal the field joints, which allowed hot gas and soot to flow past the primary O-ring. O-ring erosion occurred on all but one () of the Space Shuttle flights in 1985, and erosion of both the primary and secondary O-rings occurred on . To correct the issues with O-ring erosion, engineers at Morton Thiokol, led by
Allan McDonald and
Roger Boisjoly, proposed a redesigned field joint that introduced a metal lip to limit movement in the joint. They also recommended adding a spacer to provide additional thermal protection and using an O-ring with a larger cross section. In July1985, Morton Thiokol ordered redesigned SRB casings, with the intention of using already-manufactured casings for the upcoming launches until the redesigned cases were available the following year. crew: (back)
Onizuka,
McAuliffe,
Jarvis,
Resnik; (front)
Smith,
Scobee,
McNair.|alt=Picture of the seven crew members in flight suits and holding their helmets
Mission The Space Shuttle mission, named , was the twenty-fifth Space Shuttle flight and the tenth flight of. The crew was announced on January27,1985, and was commanded by
Dick Scobee.
Michael Smith was assigned as the pilot, and the
mission specialists were
Ellison Onizuka,
Judith Resnik, and
Ronald McNair. The two
payload specialists were
Gregory Jarvis, who was assigned to conduct research for the
Hughes Aircraft Company, and
Christa McAuliffe, who flew as part of the
Teacher in Space Project. The primary mission of the
Challenger crew was to use an
Inertial Upper Stage (IUS) to deploy
TDRS-B, a tracking and data relay satellite. The crew also planned to study
Halley's Comet as it passed near the Sun, and deploy and retrieve the
Spartan Halley satellite. The mission was originally scheduled for July1985, but was delayed to November and then to January1986. The launch date was initially set for January22, but this was delayed several times while the shuttle waited on the launch pad. On December23, 1985, due to delays in preparations for
STS-61-C, the launch was pushed back to January23. On January22, the mission was postponed until January26 due to
dust storms at the shuttle's
emergency landing site,
Dakar-Yoff International Airport in Senegal. NASA chose
Mohammed V International Airport in
Casablanca, Morocco, as an alternative emergency site, but a lack of runway lighting there meant that the shuttle now could only launch when it was daytime in Morocco and morning in Florida. The launch was postponed again by one day when thunderstorms near Cape Canaveral were forecast for January26; the weather turned out to be clear at the intended launch time, but storms came in shortly thereafter. The shuttle was prepared to launch on January27, but the countdown was halted at T−9 minutes when the crew cabin's door handle could not be removed due to a stuck bolt, preventing the needed
insulation tile from being installed in its place. By the time the bolt had been removed, high winds at Cape Canaveral prevented the launch, as they would have made a
RTLS abort dangerous if it were needed. The winds continued until the morning's launch window closed at 12:37 p.m. EST, causing one final postponement to January 28. While all of these delays were necessitated by safety concerns, the increased publicity surrounding the mission because of the Teacher in Space Program led major media outlets to ridicule the repeated postponements of the launch. On the evening of January 27, CBS's
Dan Rather called the bolt issue a "high-tech low comedy", while other outlets highlighted the frustration of spectators who had been waiting for the launch that day. This negative media coverage was later cited as one of several factors which pressured NASA officials to ignore potential issues with the O-rings so that
Challenger could launch as soon as possible. == Decision to launch ==