Project Plan Root Cause and Risk Analysis Team 2

1. Project PlanRoot Cause and Risk AnalysisTeam 2 NASA: Henning Leidecker; 301-286-9180 Boeing: Gary W. Bickel; 714-372-6820 2/25/00

2. Team 2 Members • Project Leads: Henning Leidecker-NASA/GSFC • Gary W. Bickel-Boeing/HB • Team Members: Ray Prestridge-JSC • Pete Mueggler-BHB • Carol McDonald-BHOU • Anna Cantwell-SEA • David Gill-BHB • Jeanette Plante-GSFC • Dave Rothermel-BICC • Dale Zevotek-BICC • Martin Seifert-LSFT • David Beverly-JSC • Craig Mueller-AERO • Harold Battaglia-BHOU • John Canham-GSFC

3. Task 1-Root Cause Analysis • Identify Primary Agent for “Rocket Engine Defect”--complete: HF-etch enabled by Polyimide void and carbon coating breech • Investigate Strength Reduction, ‘96 Cable--complete: 124/446 samples below Proof-Test level; Polyimide void consistently observed • need to complete microphotographs on approximately 34 samples • Investigate Strength Reduction, ‘98-9 Cable--partially complete • Determine source of Polyimide coating voids (fiber or other process) • Determine Agent (or process step) for carbon coating breech • Resolve Lingering Questions (Polyimide Canyons versus voids, SEM) • Complete Root Cause Analysis Report

4. Task 1-Root Cause: status • Microphotos on 34 Samples-deferred • Strength Tests 98-9 Cable-on hold • Polyimide Coating Voids Source: no progress • Coating Penetration Test Plan in development • SEM to sort variations in Polyimide void structure: no progress • Root Cause Report: Major sections left to write

5. Task 2-Risk AnalysisUS Lab and Node 1 • Estimate Potential Failures due to Rocket Engine Defects-- • Determine Effective “n” value--failed; insufficient data • Determine alternate model for failure prediction of existing defects/flaws • Estimate pre-flight and on-orbit failures based on strength distribution data • Determine Potential for Post-Process defect generation by Launch vibration impact • Determine Potential for on-orbit defect generation by Ionized Radiation • Prepare Risk Analysis Report for US Lab and Node 1

6. Task 2-Risk Analysis: StatusUS Lab and Node 1 • Preliminary Risk Analysis Completed • No consensus on Preliminary Risk Analysis based on “worst case” n-value • Preparing proposal to do n-value tests for ESD attack on uncabled fiber • Efforts on vibration/ionizing radiation launch & on-orbit effects on-going

7. Task 3-Risk Analysis & Reduction(Node 1 DT0 Cable, ESA Cable, all ‘98-9 Cable Use) • Determine Low Strength Distribution for ‘98-9 cable-- • Provide Preliminary Strength Tests on ESA Cable (representing ‘97 production)-- • Determine Effect of additional “Proof Testing” at the Cable level • Apply results of above in estimating risk • Prepare Risk Analysis Reports as needed for these tasks

8. Task 3-Risk Analysis & Reduction: Status(Node 1 DT0 Cable, ESA Cable, all ‘98-9 Cable Use) • Strength Tests on 98-9 cable on hold • Tests on ESA cable pending receipt of cables and funding decisions • Proof Testing fixture in development

9. Team 2--Schedule

10. Team 2--Resources Required