SPACE SHUTTLE ACCIDENTS

SPACE SHUTTE ACCIDENTS:

Two Shuttles have been destroyed in 114 missions, both with the loss of the entire crew:

Challenger — lost 73 seconds after lift-off, January 28, 1986 
Further information: STS-51-L 
Columbia — lost during re-entry, February 1, 2003 
 

With Challenger an O-ring which should not have eroded at all did erode on earlier shuttle launches. Yet managers felt because it had not previously eroded by more than 30%, that this was not a hazard as there was "a factor of three safety margin". Morton Thiokol designed and manufactured the SRBs, and during a pre-launch conference call with NASA, the Thiokol engineer most experienced with the O-rings pleaded with management repeatedly to cancel or reschedule the launch. He raised concerns that the unusually cold temperatures would stiffen the O-rings, preventing a complete seal, which was exactly what happened on the fatal flight. However, Thiokol senior managers overruled him, dismissing his safety concerns and allowed the launch to proceed. Challenger's O-rings eroded completely through as predicted, resulting in the complete destruction of the spacecraft and the loss of all seven astronauts on board.

Columbia was destroyed because of damaged thermal protection from foam debris that broke off the external tank during ascent. The foam had not been designed or expected to break off, but had been observed in the past to do so without incident. The original shuttle operational specification said the orbiter thermal protection tiles were designed to withstand virtually no debris hits at all. Over time NASA managers gradually accepted more tile damage, similar to how O-ring damage was accepted. The Columbia Accident Investigation Board called this tendency the "normalization of deviance" — a gradual acceptance of events outside the design tolerances of the craft simply because they had not been catastrophic to date.