MEMO

TO: Jim Thomas

Vice President, Engineering

FROM: Ricardo A. Vara

Applied Mechanics - Ext. 3525

SUBJECT: SRM O-Ring Erosion/Potential Failure

DATE: 20, December 1986

Background:
In order to guarantee that everyone at Marshall understands the seriousness of the O-Ring
erosion problem in the solid rocket booster (SRB) joints this memo has been written. Launching
the Challenger in the predicted 26F temperature will result in failure including the loss of the
shuttle, money, and human life because decreased O-ring resiliency in cold weather.

Problem:
Bench test data indicate[s] that the O-ring resiliency is a function of temperature and the rate
of case expansion. (Windsor 105) At 50F the [secondary] O-ring did not re-establish contact
[with the metal mating surfaces] in 10 minutes at which time the test was terminated (Windsor
105) The conclusion is that secondary sealing capability in the secondary SRM field joint
cannot be guaranteed. (Windsor 105) If the SRB joints fail to seal hot gas will escape eroding
the O-rings.

Flight data shows that all flights launched below 63F had incidents of O-ring erosion. Flight 51-
C, launched at 53F, had 3 separate incidents of erosion. Please refer to the graph on the next
page to see all cases of erosion in previous launch tests. Erosion has occurred on both the
primary and secondary O-rings. From 330 to 660 milliseconds the chance of the secondary seal
holding is small. (Windsor 105) If you guys decide to launch the Challenger shuttle below 50F
and the primary O-ring fails the secondary O-ring will fail as well; resulting in catastrophic
failure of the Challenger launch.

Suggested Action:
Data suggests launching temperatures be greater than or equal to 72F, the lowest temperature
tested without any erosion. If no action is taken the launch will be unsuccessful resulting in the
loss of the Challenger shuttle, billions of dollars, and human life. Please contact me or Mr. Roger
Boisjoly at Morton Thiokol with any questions concerning this issue.
 Works Cited

Tufte, Edward R. Visual and Statistical Thinking: Displays of Evidence for Making Decisions.

Cheshire, CT. Graphics Press LLC., 1997. Print.

Winsor, D.A. Communication Failures Contributing to the Challenger Accident: An Example for

Technical Communicators. 1988. Print.