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Inadequate methods of applying and repairing foam on the space shuttle’s fuel tank probably contributed to the dangerous loss of a chunk of the insulation during Discovery’s launch 2 months ago, a NASA investigation team concluded Friday. So much work is needed to understand the problem and correct the deficiencies that shuttle flights are on hold until at least May, and possibly even next summer.
NASA’s Richard Gilbrech, head of the investigation team, said no one may ever know exactly what caused a 1-pound, 3-foot section of foam to break off Discovery’s external fuel tank in late July. It was a scary repeat of what happened during Columbia’s doomed flight in 2003.
Another possibility is that the one-inch layer of underlying foam may have cracked because of thermal stresses, causing the layer on top to pop off.
NASA already has introduced new techniques for applying foam and is limiting workers’ access to vulnerable areas.

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