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Fresh safety probe for shuttle fleet

NASA could soon be facing renewed calls to replace its ageing space shuttle fleet. Its engineers have been trying to find out why some explosive charges in the bolts that release the shuttle from its launch pad failed to fire last month during Atlantis’s launch. If the problem looks as if it might recur, it could delay next week’s launch of Endeavour, and is likely to spark another bout of concern over the veteran fleet’s reliability.

The set of 10 bolts are fixed underneath the shuttle’s solid-rocket boosters, keeping the shuttle firmly attached to the launch pad to stop it moving around in high winds. Each bolt contains two explosive charges – primary and secondary – that are designed to detonate moments before lift-off. The shuttle can launch safely if only one set of charges detonates, but both should operate together.

NASA has never tested what might happen if both sets of charges failed to go off, but the result would probably be catastrophic. “We won’t speculate on loss of the spacecraft,” says a spokesman.

NASA says the failure of the entire set of Atlantis’s secondary charges points to a problem in either generating or transmitting the firing command to the bolts. Such problems have occurred before. Two years ago, shuttle launches were delayed after a similar problem with an explosive bolt holding one of the solid-fuel boosters to Endeavour’s giant external fuel tank. Engineers traced that failure to worn electrical cables that would not transmit the firing signal (èƵ, 23 December 2000, p 6).

The risk that both sets of charges might fail to fire led NASA to test every cable in its inventory. It found four faulty cables. But the detonation commands for the bolts come from the shuttle itself, so NASA is analysing the control system as well as the cabling. But by early this week, the engineers had not reached any conclusions.

Charles Vick, a space policy analyst based in Fredericksburg, Virginia, says that the shuttle’s explosive bolts have fail-safe notches cut into them, so the bolts should snap when subjected to launch forces. But, Vick says,if they don’t break, the vehicle, which could be free on one side yet bolted to the launch pad on the other, “becomes for all practical purposes a suicide vehicle.”

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