-----------------------------------------------------------------------
  **MSFC PRACA : 2003-02-12 07:54**

  -----------------------------------------------------------------------

  --------------------------------------------------- -------------------
                                                      

  WHOLE RECORD REPORT( + ADDENDUM)                    

                                                      
  --------------------------------------------------- -------------------

+--------------+---------------+-----------+---------+------+--------+
| **MSFC       | **In-Flight   | **C       | **      | *    |        |
| Record \#**\ | Anomaly       | ontractor | JSC#**\ | *KSC |        |
| A10330       | Number**\     | Report    | \--     | #**\ |        |
|              | \--           | Number**\ |         | \--  |        |
|              |               | T-055     |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| PDL LIFTOFF  |               |           |         |      |        |
| AT EPOXY     |               |           |         |      |        |
| PRIMER/POFI  |               |           |         |      |        |
| BONDLINE     |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **EICN#**\   | **ELEMENT**\  | **Cont    | **F     | **   |        |
| \--          | ET            | ractor**\ | SCM#**\ | FCRI |        |
|              |               | MMMSS     | \--     | T**\ |        |
|              |               |           |         | 1    |        |
+--------------+---------------+-----------+---------+------+--------+
| **HCRIT**\   | **Sys_Lvl**\  | **Misc    |         |      |        |
| \--          | N             | Codes**\  |         |      |        |
|              |               | A B C D E |         |      |        |
|              |               | **(X)** F |         |      |        |
|              |               | G H I J K |         |      |        |
|              |               | L M N O   |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| *            | **NO          | *         | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | *PART#**\ | LOT#**\ | *MAN |        |
| EIM          | ET COMPLETE   | 80        | N/A     | UFAC |        |
|              |               | 901010000 |         | TURE |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | PDL  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            | **NO          | *         | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | *PART#**\ | LOT#**\ | *MAN |        |
| LRU          | N/A           | N/A       | N/A     | UFAC |        |
|              |               |           |         | TURE |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | N/A  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            | **NO          | *         | **SER/  | *    |        |
| *HARDWARE**\ | MENCLATURE**\ | *PART#**\ | LOT#**\ | *MAN |        |
| NCA          | ET COMPLETE   | 80        | N/A     | UFAC |        |
|              |               | 901010000 |         | TURE |        |
|              |               |           |         | R**\ |        |
|              |               |           |         | MMC  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Test/      | **Prevailing  | **F /     | **Fail  | **   |        |
| Operation**\ | Condtion**\   | U**\      | Mode**\ | Caus |        |
| L - FLD      | N -           | F         | UC -    | e**\ |        |
|              | INSPECTION    |           | UNSAT   | MP - |        |
|              |               |           |         | MFG  |        |
|              |               |           |         | -PRC |        |
+--------------+---------------+-----------+---------+------+--------+
| **System**\  | **Defect**\   | **Ma      | **Work  | **   |        |
| TPS          | DD - DETACH   | terial**\ | Con     | Fail |        |
|              |               | F - INSUL | tact**\ | Dat  |        |
|              |               |           | W.      | e**\ |        |
|              |               |           | JOHNSON | 05   |        |
|              |               |           |         | /05/ |        |
|              |               |           |         | 1986 |        |
+--------------+---------------+-----------+---------+------+--------+
| **Received   | **Date        | **FMEA    | **IFA:  | *    |        |
| at MSFC**\   | Isolated**\   | Ref       | Mission | *Mis |        |
| 10/08/1986   | \--           | erence**\ | P       | sion |        |
|              |               | 1.2.3     | hase**\ | Ela  |        |
|              |               |           | \--     | psed |        |
|              |               |           |         | Tim  |        |
|              |               |           |         | e**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            |               | **S       |         | **   |        |
| *Location**\ |               | ymptom**\ |         | Time |        |
| VAFB         |               | UC -      |         | Cycl |        |
|              |               | UNSAT     |         | e**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| *            |               |           |         |      |        |
| *Effectivity |               |           |         |      |        |
| Text**\      |               |           |         |      |        |
| LWT 16 AND   |               |           |         |      |        |
| UP           |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Vehicle    |               |           |         |      |        |
| Effectivity  |               |           |         |      |        |
| Codes**      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Vehicle    | **Vehicle     | **Vehicle | **      | *    |        |
| 1**\         | 2**\          | 3**\      | Vehicle | *Veh |        |
| \--          | \--           | \--       | 4**\    | icle |        |
|              |               |           | \--     | 5**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Mission    |               |           |         |      |        |
| Effectivity  |               |           |         |      |        |
| Codes**      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Mssn 1**\  | **Mssn 2**\   | **Mssn    | **Mssn  | **   |        |
| \--          | \--           | 3**\      | 4**\    | Mssn |        |
|              |               | \--       | \--     | 5**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Estimated  |               |           |         |      |        |
| Completion   |               |           |         |      |        |
| Dates**      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **MSFC       | **Contractor  | **LVL 3   | *       |      |        |
| Approved     | Req Defer     | Close**\  | *Remark |      |        |
| Defer Until  | Until Date**\ | \--       | /       |      |        |
| Date**\      | \--           |           | Ac      |      |        |
| \--          |               |           | tion**\ |      |        |
|              |               |           | \--     |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **I          |               |           |         |      |        |
| nvestigation |               |           |         |      |        |
| / Resolution |               |           |         |      |        |
| Summary**    |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Last MSFC  | **CN RSLV     | **Defer   | **Add   | *    |        |
| Update**\    | SBMT**\       | Date**\   | Date**\ | *R/C |        |
| 01/15/1992   | 07/21/1987    | \--       | \--     | Code |        |
|              |               |           |         | s**\ |        |
|              |               |           |         | 2 -  |        |
|              |               |           |         | MFG  |        |
|              |               |           |         | \--  |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Assignee** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Design**\  | **Chief       | **S &     | **Pro   | *    |        |
| B. DAVIS     | Engineer**\   | MA**\     | ject**\ | *Pro |        |
|              | J. NICHOLS    | R.        | J.      | ject |        |
|              |               | JACKSON   | CA      | MG   |        |
|              |               |           | VALARIS | R**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Approval** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Design**\  | **Chief       | **S &     | **Pro   | *    |        |
| B. DAVIS     | Engineer**\   | MA**\     | ject**\ | *Pro |        |
|              | J. NICHOLS    | R.        | J.      | ject |        |
|              |               | JACKSON   | CA      | MG   |        |
|              |               |           | VALARIS | R**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **PAC        | **PAC Review  | **MSFC    | **St    | *    |        |
| Assignee**\  | Complete**\   | Closure   | atus**\ | *F/A |        |
| J.EL-IBRAHIM | \--           | Date**\   | C -     | C    |        |
|              |               | 0         | CLOSED  | ompl |        |
|              |               | 8/06/1987 |         | etio |        |
|              |               |           |         | n**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    | **SEV**\      | **Program | **      | **O  |        |
| Type**\      | \--           | Name**\   | REVL**\ | PRIN |        |
| \--          |               | \--       | \--     | C**\ |        |
|              |               |           |         | \--  |        |
+--------------+---------------+-----------+---------+------+--------+
| **FUNC       | **Software    | *         |         | **SU | **So   |
| MOD**\       | E             | *Software |         | BTYP | ftware |
| \--          | ffectivity**\ | Fail      |         | E**\ | C      |
|              | \-- \-- \--   | CD**\     |         | \--  | losure |
|              | \-- \--       | \--       |         |      | CD**\  |
|              |               |           |         |      | \--    |
+--------------+---------------+-----------+---------+------+--------+
| **RES PERSON | **Approval    |           |         |      |        |
| L2**\        | Signature     |           |         |      |        |
| \--          | L3**\         |           |         |      |        |
|              | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    | **Related     |           |         |      |        |
| Document     | Document      |           |         |      |        |
| Type**\      | ID**\         |           |         |      |        |
| \--          | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    |               |           |         |      |        |
| Document     |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| \--          |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    | **Related     |           |         |      |        |
| Document     | Document      |           |         |      |        |
| Type**\      | ID**\         |           |         |      |        |
| \--          | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    |               |           |         |      |        |
| Document     |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| \--          |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    | **Related     |           |         |      |        |
| Document     | Document      |           |         |      |        |
| Type**\      | ID**\         |           |         |      |        |
| \--          | \--           |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Related    |               |           |         |      |        |
| Document     |               |           |         |      |        |
| Title**\     |               |           |         |      |        |
| \--          |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Contractor |               |           |         |      |        |
| Status       |               |           |         |      |        |
| Summary**    |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Reliabi    |               |           |         |      |        |
| lity/Quality |               |           |         |      |        |
| Assurance    |               |           |         |      |        |
| Concerns,    |               |           |         |      |        |
| Recomm       |               |           |         |      |        |
| endations:** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Problem    |               |           |         |      |        |
| D            |               |           |         |      |        |
| escription** |               |           |         |      |        |
|              |               |           |         |      |        |
| REF: 1.      |               |           |         |      |        |
| AFTER        |               |           |         |      |        |
| TRIMMING TO  |               |           |         |      |        |
| REMOVE       |               |           |         |      |        |
| CRUSHED FOAM |               |           |         |      |        |
| (LO2         |               |           |         |      |        |
| FEEDLINE     |               |           |         |      |        |
| FLANGE;      |               |           |         |      |        |
|              |               |           |         |      |        |
| STATION      |               |           |         |      |        |
| 1360), IT    |               |           |         |      |        |
| WAS NOTED    |               |           |         |      |        |
| THAT PDL     |               |           |         |      |        |
| \"LIFTOFF\"  |               |           |         |      |        |
| HAD OCCURRED |               |           |         |      |        |
| AT THE       |               |           |         |      |        |
|              |               |           |         |      |        |
| EPOXY        |               |           |         |      |        |
| PRIMER/POFI  |               |           |         |      |        |
| BONDLINE. 2. |               |           |         |      |        |
| REIVEW OF    |               |           |         |      |        |
| EXTERNAL     |               |           |         |      |        |
| TANK FLIGHT  |               |           |         |      |        |
|              |               |           |         |      |        |
| SEPARATION   |               |           |         |      |        |
| PHOTOS       |               |           |         |      |        |
| INDICATE LO2 |               |           |         |      |        |
| FEEDLINE     |               |           |         |      |        |
| FLANGE PDL   |               |           |         |      |        |
| DEBOND       |               |           |         |      |        |
| DURING       |               |           |         |      |        |
| FLIGHT       |               |           |         |      |        |
|              |               |           |         |      |        |
| (POSSIBLE    |               |           |         |      |        |
| DEBRIS       |               |           |         |      |        |
| ISSUED)      |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **Contractor |               |           |         |      |        |
| In           |               |           |         |      |        |
| vestigation/ |               |           |         |      |        |
| Resolution** |               |           |         |      |        |
|              |               |           |         |      |        |
| R/C: NEW     |               |           |         |      |        |
| PROCESS HAS  |               |           |         |      |        |
| BEEN         |               |           |         |      |        |
| DEVELOPED BY |               |           |         |      |        |
| AMT WHICH    |               |           |         |      |        |
| REQUIRES THE |               |           |         |      |        |
| REDESIGN     |               |           |         |      |        |
|              |               |           |         |      |        |
| OF THE POFI  |               |           |         |      |        |
| MOLD TOOLS   |               |           |         |      |        |
| FOR THE L02  |               |           |         |      |        |
| FEED LINE    |               |           |         |      |        |
| AND THE      |               |           |         |      |        |
| THRUST STRUT |               |           |         |      |        |
|              |               |           |         |      |        |
| FLANGE CLOSE |               |           |         |      |        |
| OUTS.        |               |           |         |      |        |
| 10/9/86 -    |               |           |         |      |        |
| FAILURE      |               |           |         |      |        |
| ANALYSIS     |               |           |         |      |        |
| DETERMINED   |               |           |         |      |        |
| THE CAUSE OF |               |           |         |      |        |
|              |               |           |         |      |        |
| DEBOND IS    |               |           |         |      |        |
| THE RESULT   |               |           |         |      |        |
| OF AN        |               |           |         |      |        |
| INEFFECTIVE  |               |           |         |      |        |
| PDL POUR     |               |           |         |      |        |
| MOLD         |               |           |         |      |        |
| PRO          |               |           |         |      |        |
| CESS/TOOLING |               |           |         |      |        |
|              |               |           |         |      |        |
| 1/29/87 PRB  |               |           |         |      |        |
| STATUS - ALL |               |           |         |      |        |
| ACTIONS TO   |               |           |         |      |        |
| BE CLOSED BY |               |           |         |      |        |
| A            |               |           |         |      |        |
| PPROXIMATELY |               |           |         |      |        |
| 3-1-87       |               |           |         |      |        |
|              |               |           |         |      |        |
| MMC IS       |               |           |         |      |        |
| REVIEWING    |               |           |         |      |        |
| PROCESS TO   |               |           |         |      |        |
| ILLUMINATE   |               |           |         |      |        |
| DEBRIS.      |               |           |         |      |        |
| 2/3/87 -     |               |           |         |      |        |
| UPDATED      |               |           |         |      |        |
|              |               |           |         |      |        |
| CRITICALITY  |               |           |         |      |        |
| TO 1 THIS    |               |           |         |      |        |
| PROBLEM IS   |               |           |         |      |        |
| CONSTRAINT   |               |           |         |      |        |
| TO 61M. THIS |               |           |         |      |        |
| CONSTRAINT   |               |           |         |      |        |
| WAS          |               |           |         |      |        |
|              |               |           |         |      |        |
| COORDINATED  |               |           |         |      |        |
| WITH ET      |               |           |         |      |        |
| PROJECT      |               |           |         |      |        |
| MANAGER G.   |               |           |         |      |        |
| P. BRIDWELL. |               |           |         |      |        |
| 5/28/87 -    |               |           |         |      |        |
| PRB          |               |           |         |      |        |
|              |               |           |         |      |        |
| STATUS - MMC |               |           |         |      |        |
| IS REVIEWING |               |           |         |      |        |
| POFI MOLD    |               |           |         |      |        |
| TOOL PROCESS |               |           |         |      |        |
| FOR          |               |           |         |      |        |
| IMPROVEMENT  |               |           |         |      |        |
| AND          |               |           |         |      |        |
|              |               |           |         |      |        |
| MOD KITS TO  |               |           |         |      |        |
| BE ISSUED TO |               |           |         |      |        |
| REPAIR THE   |               |           |         |      |        |
| FLEET. ECD   |               |           |         |      |        |
| 7/16/87.     |               |           |         |      |        |
| 7/22/87 -    |               |           |         |      |        |
|              |               |           |         |      |        |
| UPDATE       |               |           |         |      |        |
| GENERAL (REF |               |           |         |      |        |
| T-055C) A.   |               |           |         |      |        |
| AN ACTION    |               |           |         |      |        |
| REQUEST      |               |           |         |      |        |
| (V-6126) WAS |               |           |         |      |        |
| RECEIVED     |               |           |         |      |        |
|              |               |           |         |      |        |
| AT MAF FROM  |               |           |         |      |        |
| VAFB FOR     |               |           |         |      |        |
| LATENT       |               |           |         |      |        |
| DEFECT       |               |           |         |      |        |
| RECURRENCE   |               |           |         |      |        |
| CONTROL PER  |               |           |         |      |        |
|              |               |           |         |      |        |
| PR-ET        |               |           |         |      |        |
| -34-TS-0022. |               |           |         |      |        |
| LOCATION:    |               |           |         |      |        |
| STATION      |               |           |         |      |        |
| 1360 - 4TH   |               |           |         |      |        |
| LEVEL -      |               |           |         |      |        |
| LWT-27       |               |           |         |      |        |
| ANOMALY:     |               |           |         |      |        |
|              |               |           |         |      |        |
| CRUSHED FOAM |               |           |         |      |        |
| ON L02       |               |           |         |      |        |
| FEEDLINE -   |               |           |         |      |        |
| 30 DEGREES   |               |           |         |      |        |
| AFTER        |               |           |         |      |        |
| TRIMMING TO  |               |           |         |      |        |
| REMOVED      |               |           |         |      |        |
|              |               |           |         |      |        |
| CRUSHED      |               |           |         |      |        |
| FOAM, IT WAS |               |           |         |      |        |
| NOTED THAT   |               |           |         |      |        |
| PDL \"LIFT   |               |           |         |      |        |
| OFF\" HAD    |               |           |         |      |        |
| OCCURRED AT  |               |           |         |      |        |
| THE          |               |           |         |      |        |
|              |               |           |         |      |        |
| EPOXY        |               |           |         |      |        |
| PRIMER/POFI  |               |           |         |      |        |
| BONDLINE. B. |               |           |         |      |        |
| EXTERNAL     |               |           |         |      |        |
| TANK         |               |           |         |      |        |
| SEPARATION   |               |           |         |      |        |
| FLIGHT       |               |           |         |      |        |
| PHOTOS       |               |           |         |      |        |
|              |               |           |         |      |        |
| DEPICT A     |               |           |         |      |        |
| LOSS OF PDL  |               |           |         |      |        |
| FOAM FROM    |               |           |         |      |        |
| THE L02      |               |           |         |      |        |
| FEEDLINE     |               |           |         |      |        |
| FLANGE       |               |           |         |      |        |
| CLOSEOUTS.   |               |           |         |      |        |
| C. AS        |               |           |         |      |        |
|              |               |           |         |      |        |
| A RESULT OF  |               |           |         |      |        |
| AR V-6126,   |               |           |         |      |        |
| AMELIORATION |               |           |         |      |        |
| OF THE       |               |           |         |      |        |
| EXISTING     |               |           |         |      |        |
| POFI MOLD    |               |           |         |      |        |
| PROCESS      |               |           |         |      |        |
|              |               |           |         |      |        |
| WAS          |               |           |         |      |        |
| EXPEDITED TO |               |           |         |      |        |
| SUP- PORT    |               |           |         |      |        |
| THE          |               |           |         |      |        |
| VALIDATION   |               |           |         |      |        |
| OF A NEW     |               |           |         |      |        |
| POFI MOLD    |               |           |         |      |        |
|              |               |           |         |      |        |
| TOOL/PROCESS |               |           |         |      |        |
| FOR LWTS 37  |               |           |         |      |        |
| AND UP; TO   |               |           |         |      |        |
| AFFECT THE   |               |           |         |      |        |
| VALIDA- TION |               |           |         |      |        |
| OF           |               |           |         |      |        |
|              |               |           |         |      |        |
| PROCESSES    |               |           |         |      |        |
| FOR PREVIOUS |               |           |         |      |        |
| BUILT        |               |           |         |      |        |
| VEHICLES     |               |           |         |      |        |
| (LWTS 16     |               |           |         |      |        |
| THROUGH 36). |               |           |         |      |        |
| D. TASKS I   |               |           |         |      |        |
|              |               |           |         |      |        |
| THROUGH IV   |               |           |         |      |        |
| OF THIS      |               |           |         |      |        |
| CAPS,        |               |           |         |      |        |
| ADDRESSES    |               |           |         |      |        |
| THE FAILURE  |               |           |         |      |        |
| ANALYSIS OF  |               |           |         |      |        |
| THE L02 POFI |               |           |         |      |        |
|              |               |           |         |      |        |
| FEEDLINE     |               |           |         |      |        |
| CLOSE- OUT   |               |           |         |      |        |
| FLANGE,      |               |           |         |      |        |
| PROCESS      |               |           |         |      |        |
| A            |               |           |         |      |        |
| MELIORATION, |               |           |         |      |        |
| CORRECTIVE   |               |           |         |      |        |
| ACTION FOR   |               |           |         |      |        |
|              |               |           |         |      |        |
| PREVIOUS     |               |           |         |      |        |
| BUILT        |               |           |         |      |        |
| VEHICLES,    |               |           |         |      |        |
| AND CONTROL  |               |           |         |      |        |
| TO PREVENT   |               |           |         |      |        |
| RECURRENCE.  |               |           |         |      |        |
| TASK I -     |               |           |         |      |        |
|              |               |           |         |      |        |
| CORRECTIVE   |               |           |         |      |        |
| ACTION A.    |               |           |         |      |        |
| THE L02      |               |           |         |      |        |
| FEEDLINE AND |               |           |         |      |        |
| THRUST STRUT |               |           |         |      |        |
| FLANGE POFI  |               |           |         |      |        |
| MOLD         |               |           |         |      |        |
|              |               |           |         |      |        |
| CLOSEOUT     |               |           |         |      |        |
| PROCESSES    |               |           |         |      |        |
| ARE          |               |           |         |      |        |
| VALIDATED BY |               |           |         |      |        |
| A COMMIT-    |               |           |         |      |        |
| TEE OF MMC   |               |           |         |      |        |
| AND AMT      |               |           |         |      |        |
|              |               |           |         |      |        |
| PERSONNEL.   |               |           |         |      |        |
| AMELIORATION |               |           |         |      |        |
| OF THE       |               |           |         |      |        |
| PROCESSES    |               |           |         |      |        |
| INCLUDED     |               |           |         |      |        |
| FABRICATION  |               |           |         |      |        |
| OF NEW       |               |           |         |      |        |
|              |               |           |         |      |        |
| POFI MOLD    |               |           |         |      |        |
| TOOLS. TWO   |               |           |         |      |        |
| SUCCESSIVE,  |               |           |         |      |        |
| SUCCESSFUL   |               |           |         |      |        |
| RUNS WERE    |               |           |         |      |        |
| PERFORMED ON |               |           |         |      |        |
| EACH         |               |           |         |      |        |
|              |               |           |         |      |        |
| FLANGE WITH  |               |           |         |      |        |
| SUBSTRATE    |               |           |         |      |        |
| BOND         |               |           |         |      |        |
| TENSION,     |               |           |         |      |        |
| SHORE \"A\"  |               |           |         |      |        |
| HARDNESS,    |               |           |         |      |        |
| SOFI FOAM    |               |           |         |      |        |
|              |               |           |         |      |        |
| DUROMETER,   |               |           |         |      |        |
| AND INTERNAL |               |           |         |      |        |
| VOIDS        |               |           |         |      |        |
| MEETING THE  |               |           |         |      |        |
| PROCESS RE-  |               |           |         |      |        |
| QUIREMENTS   |               |           |         |      |        |
|              |               |           |         |      |        |
| (REFERENCE   |               |           |         |      |        |
| INTEROFFICE  |               |           |         |      |        |
| MEMORANDUM   |               |           |         |      |        |
| 369          |               |           |         |      |        |
| 3-87-MK-017, |               |           |         |      |        |
| MK-006,      |               |           |         |      |        |
| MK-011;      |               |           |         |      |        |
|              |               |           |         |      |        |
| 369          |               |           |         |      |        |
| 3-86-DB-364; |               |           |         |      |        |
| 36           |               |           |         |      |        |
| 93-86-MK-398 |               |           |         |      |        |
| AND          |               |           |         |      |        |
| 3693         |               |           |         |      |        |
| -87-TW-206). |               |           |         |      |        |
| LWT -37 WAS  |               |           |         |      |        |
| THE          |               |           |         |      |        |
|              |               |           |         |      |        |
| PATH FINDER  |               |           |         |      |        |
| VEHICLE USED |               |           |         |      |        |
| FOR FIRST    |               |           |         |      |        |
| PART         |               |           |         |      |        |
| V            |               |           |         |      |        |
| ERIFICATION. |               |           |         |      |        |
| B. A DEBRIS  |               |           |         |      |        |
|              |               |           |         |      |        |
| ASSESSMENT   |               |           |         |      |        |
| TEAM         |               |           |         |      |        |
| REVIEWED     |               |           |         |      |        |
| FLIGHT       |               |           |         |      |        |
| SEPARATION   |               |           |         |      |        |
| PHOTOS,      |               |           |         |      |        |
| ENGINEERING  |               |           |         |      |        |
|              |               |           |         |      |        |
| (            |               |           |         |      |        |
| DRAWING/STP) |               |           |         |      |        |
| REQUIRE-     |               |           |         |      |        |
| MENTS,       |               |           |         |      |        |
| PROCESSING   |               |           |         |      |        |
| PLANS        |               |           |         |      |        |
| (MPP/PI),    |               |           |         |      |        |
|              |               |           |         |      |        |
| DEVELOPMENT  |               |           |         |      |        |
| /VERIFICATIO |               |           |         |      |        |
| N/VALIDATION |               |           |         |      |        |
| HISTORY,     |               |           |         |      |        |
| THERMAL AND  |               |           |         |      |        |
| AEROLOADING  |               |           |         |      |        |
|              |               |           |         |      |        |
| CONCERNS,    |               |           |         |      |        |
| AND THE      |               |           |         |      |        |
| IMPACTS OF   |               |           |         |      |        |
| REWORK TO    |               |           |         |      |        |
| DETERMINE    |               |           |         |      |        |
| L02 FEEDLINE |               |           |         |      |        |
| PDL          |               |           |         |      |        |
|              |               |           |         |      |        |
| DEBOND       |               |           |         |      |        |
| SIMILAR      |               |           |         |      |        |
| DE           |               |           |         |      |        |
| BRIS/PROCESS |               |           |         |      |        |
| CONCERNS.    |               |           |         |      |        |
| EXTERNAL     |               |           |         |      |        |
| TANK FLEET   |               |           |         |      |        |
| REWORK OF    |               |           |         |      |        |
|              |               |           |         |      |        |
| THE L02      |               |           |         |      |        |
| FEEDLINE AND |               |           |         |      |        |
| THRUST STRUT |               |           |         |      |        |
| FLANGES WAS  |               |           |         |      |        |
| THE TEAM     |               |           |         |      |        |
| RE           |               |           |         |      |        |
| COMMENDATION |               |           |         |      |        |
|              |               |           |         |      |        |
| (REFERENCE   |               |           |         |      |        |
| INTEROFFICE  |               |           |         |      |        |
| MEMORANDUM   |               |           |         |      |        |
| 3571-86-46). |               |           |         |      |        |
| SUBSEQUENT-  |               |           |         |      |        |
| LY, THE      |               |           |         |      |        |
|              |               |           |         |      |        |
| THRUST STRUT |               |           |         |      |        |
| FLANGE       |               |           |         |      |        |
| CLOSEOUT WAS |               |           |         |      |        |
| INCLUDED AS  |               |           |         |      |        |
| A CORRECTIVE |               |           |         |      |        |
| ACTION,      |               |           |         |      |        |
|              |               |           |         |      |        |
| HEREIN. -    |               |           |         |      |        |
| CLOSURE      |               |           |         |      |        |
| SUMMARY - A  |               |           |         |      |        |
| LATENT       |               |           |         |      |        |
| DEFECT       |               |           |         |      |        |
| (DEBONDED    |               |           |         |      |        |
| PDL L02      |               |           |         |      |        |
| FLANGE       |               |           |         |      |        |
|              |               |           |         |      |        |
| CLOSEOUT)    |               |           |         |      |        |
| DISCOVERED   |               |           |         |      |        |
| AT VAFB,     |               |           |         |      |        |
| LWT-27, AND  |               |           |         |      |        |
| EXTERNAL     |               |           |         |      |        |
| TANK FLIGHT  |               |           |         |      |        |
|              |               |           |         |      |        |
| SEPARATION   |               |           |         |      |        |
| PHOTOS       |               |           |         |      |        |
| (DEPICTING A |               |           |         |      |        |
| LOSS OF PDL  |               |           |         |      |        |
| FOAM         |               |           |         |      |        |
| MATERIAL     |               |           |         |      |        |
| DURING       |               |           |         |      |        |
| FLIGHT)      |               |           |         |      |        |
|              |               |           |         |      |        |
| VERIFIED AN  |               |           |         |      |        |
| EXISTING     |               |           |         |      |        |
| INADEQUATE   |               |           |         |      |        |
| POFI MOLD    |               |           |         |      |        |
| PROCESS. AN  |               |           |         |      |        |
| I            |               |           |         |      |        |
| NVESTIGATION |               |           |         |      |        |
|              |               |           |         |      |        |
| INTO THIS    |               |           |         |      |        |
| PHENOMENA    |               |           |         |      |        |
| SHOWED THAT  |               |           |         |      |        |
| THE          |               |           |         |      |        |
| INCUMBENT    |               |           |         |      |        |
| POFI MOLD    |               |           |         |      |        |
| TOOLING WAS  |               |           |         |      |        |
| NOT          |               |           |         |      |        |
|              |               |           |         |      |        |
| SECURED      |               |           |         |      |        |
| SUFFICIENTLY |               |           |         |      |        |
| TO PRECLUDE  |               |           |         |      |        |
| FOAM VOIDS   |               |           |         |      |        |
| DURING       |               |           |         |      |        |
| MATERIAL     |               |           |         |      |        |
| RISE. IN     |               |           |         |      |        |
|              |               |           |         |      |        |
| ADDITION,THE |               |           |         |      |        |
| METHOD       |               |           |         |      |        |
| UTILIZED IN  |               |           |         |      |        |
| THE FOAM     |               |           |         |      |        |
| CHARGING OF  |               |           |         |      |        |
| THE MOLD     |               |           |         |      |        |
| CREATED      |               |           |         |      |        |
|              |               |           |         |      |        |
| IRREGULAR    |               |           |         |      |        |
| BOND LINES.  |               |           |         |      |        |
| THIS LED TO  |               |           |         |      |        |
| FOAM RUNOVER |               |           |         |      |        |
| AND          |               |           |         |      |        |
| SEPARATION   |               |           |         |      |        |
| OF           |               |           |         |      |        |
|              |               |           |         |      |        |
| MATERIAL     |               |           |         |      |        |
| FROM         |               |           |         |      |        |
| SUBSTRATE.   |               |           |         |      |        |
| SIMULATION   |               |           |         |      |        |
| OF THE       |               |           |         |      |        |
| INCUMBENT    |               |           |         |      |        |
| POFI MOLD    |               |           |         |      |        |
| PROCESS      |               |           |         |      |        |
|              |               |           |         |      |        |
| WAS          |               |           |         |      |        |
| PERFORMED IN |               |           |         |      |        |
| THE ADVANCED |               |           |         |      |        |
| M            |               |           |         |      |        |
| ANUFACTURING |               |           |         |      |        |
| TECHNOLOGYL  |               |           |         |      |        |
| ABORATORIES. |               |           |         |      |        |
| AN           |               |           |         |      |        |
|              |               |           |         |      |        |
| IMPROVED     |               |           |         |      |        |
| PROCESS WAS  |               |           |         |      |        |
| THEN         |               |           |         |      |        |
| DEVELOPED BY |               |           |         |      |        |
| AMT (REF.    |               |           |         |      |        |
| ATTACHMENT   |               |           |         |      |        |
| 1). TENSILE  |               |           |         |      |        |
|              |               |           |         |      |        |
| TESTS ANDTHE |               |           |         |      |        |
| DISSECTION   |               |           |         |      |        |
| OF THE FOAM  |               |           |         |      |        |
| MATERIAL     |               |           |         |      |        |
| (D           |               |           |         |      |        |
| ETERMINATION |               |           |         |      |        |
| OF VOID      |               |           |         |      |        |
|              |               |           |         |      |        |
| ANOMALIES),  |               |           |         |      |        |
| WERE THE     |               |           |         |      |        |
| PHYSICAL     |               |           |         |      |        |
| PARAMETERS   |               |           |         |      |        |
| USED TO      |               |           |         |      |        |
| INDICATE AN  |               |           |         |      |        |
| IMPROVED     |               |           |         |      |        |
|              |               |           |         |      |        |
| PROCESS.     |               |           |         |      |        |
| SUBSEQUENT   |               |           |         |      |        |
| RESULTS      |               |           |         |      |        |
| SHOWED A     |               |           |         |      |        |
| SIGNIFICANT  |               |           |         |      |        |
| PROCESS      |               |           |         |      |        |
| IMPROVEMENT  |               |           |         |      |        |
|              |               |           |         |      |        |
| (REF.        |               |           |         |      |        |
| ATTACHMENT   |               |           |         |      |        |
| 2). THE NEW  |               |           |         |      |        |
| PROCESS      |               |           |         |      |        |
| REQURIED THE |               |           |         |      |        |
| REDESIGN OF  |               |           |         |      |        |
| THE POFI     |               |           |         |      |        |
|              |               |           |         |      |        |
| MOLD TOOLS   |               |           |         |      |        |
| FOR THE L02  |               |           |         |      |        |
| FEEDLINE AND |               |           |         |      |        |
| THE THRUST   |               |           |         |      |        |
| STRUT        |               |           |         |      |        |
| CLOSEOUTS.   |               |           |         |      |        |
| THE PDL      |               |           |         |      |        |
|              |               |           |         |      |        |
| FOAM WAS     |               |           |         |      |        |
| POURED INTO  |               |           |         |      |        |
| THE NEW MOLD |               |           |         |      |        |
| C            |               |           |         |      |        |
| ONFIGURATION |               |           |         |      |        |
| IN TWO       |               |           |         |      |        |
| STEPS. AFTER |               |           |         |      |        |
| THE          |               |           |         |      |        |
|              |               |           |         |      |        |
| FIRST POUR,  |               |           |         |      |        |
| THE POFI     |               |           |         |      |        |
| INTERFACES   |               |           |         |      |        |
| WERE SANDED  |               |           |         |      |        |
| SMOOTH,      |               |           |         |      |        |
| ADHESIVE     |               |           |         |      |        |
| APPLIED,     |               |           |         |      |        |
|              |               |           |         |      |        |
| AND THE      |               |           |         |      |        |
| SECOND POUR  |               |           |         |      |        |
| WAS          |               |           |         |      |        |
| PERFORMED,   |               |           |         |      |        |
| CREATING A   |               |           |         |      |        |
| RELIABLE     |               |           |         |      |        |
|              |               |           |         |      |        |
| MATERI       |               |           |         |      |        |
| AL-SUBSTRATE |               |           |         |      |        |
| BOND. THE    |               |           |         |      |        |
| AMT          |               |           |         |      |        |
| DEVELOPED    |               |           |         |      |        |
| PROCESS WAS  |               |           |         |      |        |
| VALIDATED    |               |           |         |      |        |
| FOR          |               |           |         |      |        |
|              |               |           |         |      |        |
| EACH NEW     |               |           |         |      |        |
| POFI MOLD    |               |           |         |      |        |
| TOOL USED.   |               |           |         |      |        |
| THE FIRST    |               |           |         |      |        |
| PART         |               |           |         |      |        |
| VERIFICA-    |               |           |         |      |        |
| TION WAS     |               |           |         |      |        |
|              |               |           |         |      |        |
| WITNESSED    |               |           |         |      |        |
| TWICE BY THE |               |           |         |      |        |
| VALIDATION   |               |           |         |      |        |
| COMMITTEE    |               |           |         |      |        |
| (MMC AND MAT |               |           |         |      |        |
| PERSONNEL)   |               |           |         |      |        |
|              |               |           |         |      |        |
| DURING THE   |               |           |         |      |        |
| LWT-37       |               |           |         |      |        |
| BUILDCYCLE.  |               |           |         |      |        |
| SUBSEQUENT   |               |           |         |      |        |
| MOLD         |               |           |         |      |        |
| VALIDATIONS  |               |           |         |      |        |
| WERE         |               |           |         |      |        |
|              |               |           |         |      |        |
| PERFORMED    |               |           |         |      |        |
| (SIMULATED   |               |           |         |      |        |
| IN THE AMT   |               |           |         |      |        |
| LABORATORY)  |               |           |         |      |        |
| ON THE POFI  |               |           |         |      |        |
| MOLD TOOLS   |               |           |         |      |        |
|              |               |           |         |      |        |
| WHICH WILL   |               |           |         |      |        |
| BE UTILIZED  |               |           |         |      |        |
| (FOR FLANGE  |               |           |         |      |        |
| CLOSEOUT)    |               |           |         |      |        |
| WHEN THE     |               |           |         |      |        |
| EXTERNAL     |               |           |         |      |        |
| TANK IS      |               |           |         |      |        |
|              |               |           |         |      |        |
| IN THE       |               |           |         |      |        |
| VERITICAL    |               |           |         |      |        |
| POSITION     |               |           |         |      |        |
| (KSC).       |               |           |         |      |        |
| R            |               |           |         |      |        |
| EWORK/REPAIR |               |           |         |      |        |
| OF THE FLEET |               |           |         |      |        |
| CLOSEOUT     |               |           |         |      |        |
|              |               |           |         |      |        |
| FLANGES (AS  |               |           |         |      |        |
| DETAILED,    |               |           |         |      |        |
| HEREIN) WILL |               |           |         |      |        |
| BE           |               |           |         |      |        |
| ACCOMPLISHED |               |           |         |      |        |
| PER MODIFI-  |               |           |         |      |        |
| CATION       |               |           |         |      |        |
|              |               |           |         |      |        |
| KITS         |               |           |         |      |        |
| (REFERENCE   |               |           |         |      |        |
| B01777).     |               |           |         |      |        |
| THIS PROBLEM |               |           |         |      |        |
| IS SUBMITTED |               |           |         |      |        |
| TO MSFC FOR  |               |           |         |      |        |
| REVIEW       |               |           |         |      |        |
|              |               |           |         |      |        |
| AND APPROVAL |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+
| **MSFC       |               |           |         |      |        |
| Response/C   |               |           |         |      |        |
| oncurrence** |               |           |         |      |        |
+--------------+---------------+-----------+---------+------+--------+

  ---------------- ----------------- ---------------- ----------- ----------- ------------ --
                                                                                           

  ASSESSMENT                                                                               
  ADDENDUM REPORT                                                                          

  **MSFC           **IFA#**\         **Contractor     **JSC#**\   **KSC#**\   **EICN#**\   
  Report#**\       \--               RPT#**\          \--         \--         \--          
  A10330                             T-055                                                 

  **Asmnt Part#**\ **Asmnt Part      **Asmnt                                               
  80901010000      Name**\           Serial/Lot#**\                                        
                   ET COMPLETE       N/A                                                   

  **HCRIT CD**\    **FCRIT CD**\     **CAUSE CD**\    **FAIL                               
  \--              1                 MP - MFG-PRC     MODE**\                              
                                                      UC - UNSAT                           

  **Asmnt FMEA**\  **Asmnt FM**\     **FMEA CSE**\    **FMEA                               
  5.8.1.1          1                 B                SCSE**\                              
                                                      3                                    

  **Asmnt FMEA**\  **Asmnt FM**\     **FMEA CSE**\    **FMEA                               
  \--              \--               \--              SCSE**\                              
                                                      \--                                  

  **Asmnt FMEA**\  **Asmnt FM**\     **FMEA CSE**\    **FMEA                               
  \--              \--               \--              SCSE**\                              
                                                      \--                                  

  **Correlated     **Correlated      **Correlated                                          
  Part#**\         Part#**\          Part#**\                                              
  \--              \--               \--                                                   

  **Associated     **Associated      **Associated                                          
  LRU#**\          LRU#**\           LRU#**\                                               
  \--              \--               \--                                                   

  **MAJOR DESIGN                                                                           
  CHANGES**                                                                                

  **APRV DATE**\   **DESCRIPTION OF                                                        
  \--              CHANGES**\                                                              
                   \--                                                                     

  **ASSESSMENT                                                                             
  TEXT**                                                                                   
  ---------------- ----------------- ---------------- ----------- ----------- ------------ --