Abstract
Various aluminum parts, both castings and rolled sheet, were found among the Columbia debris. At first glance, these parts seemed to have failed in a brittlelike manner, contrary to normal aluminum fracture behavior. Light optical microscopy on the etched aluminum samples examined in this study revealed second-phase particles along the grain boundaries. It was also observed that at the elevated temperatures encountered during re-entry, some of the particles melted and wetted the grain boundaries. Large voids could be found between the grains near the crack tips. Energy-dispersive spectroscopy showed particles that were rich in iron. During re-entry of the shuttle, elevated temperatures caused melting of the second-phase particles, allowing them to wet the grain boundaries, a process called liquation. Cracks initiated and propagated through the grain boundaries, thus resulting in intergranular rupture that had the macroscopic characteristics of brittle failure of the aluminum.
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References
Columbia Accident Investigation Board (CAIB): Report Volume 1, NASA, Aug 2003.
B.M. Mayeaux, T.E. Collins, G.A. Jerman, S.J. McDanels, R.S. Piascik, R.W. Russell, and S.R. Shah: “Materials Analysis: A Key to Unlocking the Mystery of the Columbia Tragedy,” J. Met., Feb 2004, p. 20.
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Lam, I., Ganot, G., Brundage, D. et al. Failure analysis of aluminum structural members on the space shuttle Columbia. J Fail. Anal. and Preven. 6, 32–38 (2006). https://doi.org/10.1361/154770206X86545
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DOI: https://doi.org/10.1361/154770206X86545