Benefits and Impacts Obsolescence Reduction Risk Reduction Safety Improvement Cost Reduction

1. Electrostatic ET Foam Application Area(s) of Significant Benefit Safety Performance Sustainability Operations Infrastructure • Description • A method and tools to apply ET foam electro-statically would be developed. • An increase in the tank/foam bond strength would result furthermore reducing or eliminating air gaps between the foam and tank • Strengthened bond would reduce the incidence ET foam separating from the tank during Space Shuttle launch causing damage to Orbiter tiles. • Technologies and Capabilities • The surface aerodynamics would not be changed • A more efficient bond of the ET foam to the ET, thus reducing the incidence of foam separating from the ET • Due to the maturity of commercial electrostatic paint systems, the development of the tool and processes is expected to be rapid • Development of a patentable process for commercial use Benefits and Impacts Obsolescence Reduction Risk Reduction Safety Improvement Cost Reduction Process Improvement Other (Ultra-High Operations Improvement Reliability) Performance Enhancement • POC, Cost, Schedule and Maturity • TRL 2 Electrostatic Foam Application Tools and Process • POC: Greg Hall, KSC (321-867-6976) • A Substantial reduction in incidence of Orbiter Vehicle tile damage caused by ET foam • B Change in processes is minimal, with no change in vehicle performance • Reduction in Criticality 1 Failure Rate of 0.01%

2. Electrostatic ET Foam Application • Total Project Costs: $ 5.6 M • Obsolescence & Feasibility: $ 0.25 M • Formulation: $ 0.25 M • Implementation: $ 5.0 M • Project Submitted By: Greg Hall, KSC and James Fesmire • Note: Supplemental Information attached in MS Word document