NASA/TM-1999-209824

Liberty Bell 7 Recovery Evaluation and

Nondestructive Testing

Eric I. Madaras and William L. Smith

Langley Research Center, Hampton, Virginia

December 1999

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NASA/TM-1999-209824

Liberty Bell 7 Recovery Evaluation and

Nondestructive Testing

Eric I. Madaras and William L. Smith

Langley Research Centel, Hampton, Virginia

National Aeronautics and

Space Administration

Langley Research Center

Hampton, Virginia 23681_2199

December 1999
Acknowledgments

The NASA Liberty Bell 7 Recovery Team would like to thank the following organizations and individuals for their

cooperation, facilitation, and professional expertise during the exercising of the NASA terms and conditions regarding

the capsule:

Discovery Communications Inc.

Michael T. Prettyman, Vice President Business Affairs

Britta von Schoeler, Business Affairs

Suzy Geller, Producer

Kansas Cosmospherc and Space Center:

Max Airy, Director and CEO

Jeff Ollcnburger, Vice President of Marketing & Programs

Karen Seibcrt, Marketing Director

NASA Johnson Space Center:

James L. Lewis, Branch Chief, Space Human Factors Branch

Hill Air Force Base

Don Wickham, Captain (Retired)

Available from:

NASA Center for AeroSpace Information (CASI)

7121 Standard Drive

Hanover, MD 21076-1320

(301) 621-0390

National Technical Information Sen, ice (NTIS)

5285 Port Royal Road

Springfield, VA 22161-2171

(703) 605-6000

This report is also available in electronic form at URL http://techreports.larc.nasa.go\_ltrs/
Abstract

An inspection of the Mercury capsule, Liber_' Bell 7, and its contents was made on September 1 and 2, 1999. The condition of the capsule and its contents was consistent with long-term exposure to salt

water a#td high pressures at the bottom of the ocean. Many of the

metallic materials suffered corrosion, whereas the polymer-based

materials seem to have survived remarkably well. No identifiable items

or structures were found that appeared to have any scientific value. At

this time, no further nondestructive evaluation appears to be justified.

Introduction

On April 16, 1999, an expedition funded by Discovery Communications Inc. left Cape Canaveral,

FL, to search for the Mercury capsule, Liberty Bell 7, which sank to the bottom of the Atlantic Ocean on

July 21, 1961. During that expedition, the expeditionary crew successfully located the Liberty Bell 7 by

using recently developed sonar maps and a remotely operated vehicle. Recovery took place on a subsequent expedition, and the space capsule was returned to port on July 21, 1999, exactly 38 years after its

historic flight. Figure 1 shows the capsule as it was viewed on the bottom of the ocean (fig. l(a)) and

after being brought to the surface prior to being placed into a transportation/storage vessel (fig. 1(b)).

With the recovery of Liberty Bell 7, NASA had an opportunity to evaluate nondestructively the condition of the capsule. The Langley Research Center (LaRC) was tasked by the NASA Office of Space

Flight to lead an Agency effort to inspect and conduct nondestructive analysis if warranted on the

Liberty Bell 7 capsule in accordance with a memorandum of understanding (MOU) between NASA and

Discovery Communications Inc. The Liberty Bell 7 capsule, which had been in salt water for 38 years,

was recovered by an effort sponsored by Discovery Communications Inc. Langley Research Center

formed a team including a member from the Johnson Space Center (JSC) to exercise the terms and conditions of the MOU where practical; this team was called the NASA Liberty Bell 7 Recovery Team.

(a) View on bottom of ocean. (b) View after being brought to surface.

Figure 1. Libert)' Bell 7 capsule. Photographs courtesy of Discovery Communications Inc.
For more information about the recovery and condition of the Liberty Bell 7, see the bibliography.

Charter and Team

Langley Research Center was tasked by the NASA Office of Space Flight to lead an Agency effort

at the advent of the recovery of the Mercury capsule, that was sponsored by Discover)' Communication

Inc. to exercise the limited rights for the inspection and nondestructive evaluation (NDE) of the capsule

which had been in salt water for 38 years.

The following table shows the NASA Liberty Belt 7 Recovery Team formed by LaRC to conduct

the inspection and evaluation:

Member Expertise Role/Center

William L. Smith Lead/LaRC

Michael E Finneran

John B. Hall

Robert D. Legler

Eric I. Madaras

Kenneth G. Wilson

Human and robotic space systems design,

development, and flight operations

Public affairs

Human spacecraft systems and subsystems

Human Space Flight Historian

Systems NDE testing analyses

Legal

Public Affairs OfficerFLaRC

Technical/LaRC

Historian/JSC

Technical/LaRC

Legal/LaRC

Assumptions

The first task was to try to identify elements of the capsule whose testing could provide scientific

value. Inquiries with material scientists and engineers at JSC and LaRC confirmed that the materials and

structures used on this capsule were obsolete and of little modem value. An additional complication was

the fact that after being submerged in the Atlantic Ocean for nearly 38 years, many of the materials

would undoubtedly be compromised. One specific item that was discussed was the possible condition of

the thermal protection system (TPS). Initially the committee thought that the TPS on the Liberty Bell 7

was of a phenolic variety. Although phenolic TPS is an old style of TPS, systems like this are occasionally revisited from time to time. Data on this TPS could be added to the database obtained from the

other Mercury flights. In generai, though, it was difficult to foresee what specific scientific tests should

be done on the capsule without a preliminary investigation.

With this guidance, a few methods for tests that could be undertaken to acquire a preliminary view

of the Liberty Bell 7 and to archive the state of the capsule for further consideration are as follows:

l° With respect to the TPS, ultrasound might possibly be used to test such a structure. Thiokol

Corporation experimented with this technology in reference to solid rocket motor nozzle throat

erosion (private communication with Lee Pearson of Thiokol Corp.), and it might be possible to

document the char thickness, if any, and the remaining thickness of the ablator.

. Undertaking a complete photographic study of the capsule for NASA and public use would seem

rather straightforward. This study could include close-ups as well as comprehensive views of the

capsule.

. A unique technology that could actually view the inside of the structure is x-ray computed

tomography (CT). Because of the size of the capsule, only a few systems are probably available

that could accomplish this task. For example, a large CT system at Hill Air Force Base (AFB)

2
outside Salt Lake City, UT, can scan objects up to approximately 2.4 meters in diameter. Also,

the U.S. Navy has several systems that can scan objects with diameters of approximately

2.2 meters. If arrangements could be made, this system could actually scan an appropriately

sized container accommodating both the capsule and its water bath to provide a threedimensional view of the capsule, including structures within and behind the walls. Then this

computer database would be available to engineers and scientists in the future. In addition, this

information could be used to address the TPS dimensions.

For each of these methods, the cost, risks, and potential benefits were reviewed. First, the ultrasonic

study of the TPS would have only taken a week or two and would not have involved much manpower.

The potential risks were related to the uncertainty on several points with this measurement. The first

point dealt with the condition of the TPS and knowledge of the ultrasonic properties of the material. To

measure the thickness of the material, the ultrasonic velocity needed to be known. Sitting on the ocean

floor for many years may have allowed some unknown material changes to take place in the TPS that

could not be anticipated. Therefore, the velocity values for the ultrasound in the TPS might be only an

estimate in this material and would require some sort of calibration to acquire; calibration might not be

possible. Also the surface of the TPS might be partially charred with the rest intact; this would greatly

complicate the measurement. Having burned and unburned components would require additional information to ascertain the relative thickness if it was possible. The second point touches on the geometry

and access. How easy the access to the TPS would be is not clear, and data acquisition could be limited.

Also, the surface might be so uneven that it would hamper the accuracy of the data.

The second suggested method, photographic evaluation, like the first method would have only taken

a week or two and would not have involved much manpower. The costs for film processing were not

expected to be exorbitant. The risk in obtaining these data was mostly related to geometry and access to

the surfaces of the capsule. Another issue was duplication of effort because much of this information

might be available from the organizations that recovered the Liberty Bell 7. Because they were also

interested in documenting the capsule, they would probably have taken many photographs making this

effort redundant.

The third method suggested would be the most costly. It would involve transporting the capsule to

the CT site, making the measurements, and then transporting the capsule back to its original site; this

would take about 2 to 3 weeks. In addition, the amount of data taken would be enormous and would

require a few weeks to process. If more sophisticated processing was required, manpower needs could

approach 6 months. The cost would encompass transportation, handling, facility usage expenses, and

analysis manpower. The risks for this effort were related to several uncertainties. The first uncertainty

again deals with geometry. The whole object could be scanned provided it is less than 2.44 meters in

diameter. (See fig. 2.) Scanning the capsule and container together would require careful planning.

Could the capsule be removed from its container or would it be in a correctly sized container? Also, at

Hill AFB and the Navy bases, the operations are configured and designed to handle various large missiles with equipment to lift and handle these missiles. How that equipment and handling procedures

could be adapted to handling the capsule and container would also require careful planning. Finally,

some sort of agreement between the Air Force or the Navy and NASA would be necessary to utilize

their facilities. The facility operators were supportive of this type of project, but they were unsure of the

procedure for working with nonmilitary organizations. Additional risks would be involved in transporting the capsule to another site, including potential damage caused by truck vibrations or a possible truck

accident.

3
(a)OneCTsystemscanningamissile. (b)LargeCTsystemwherecapsuleandcontainerwould

havetofit betweenthetwolargegantries(onleft)onlarge

turntable(incenter).

Figure2.CTsystemsatHill AFB.Photographs courtesyofAdvancedResearch& AppliedApplications

Corporation(ARACOR).

Preliminary Inspection

Based on these foregoing ideas, the decision was made that a visit to the site where the capsule was

being stored, the Kansas Cosmosphere and Space Center, Hutchinson, KS, and to a site where CT could

be performed would be the best way to evaluate the various opportunities. At Cosmosphere, the capsule

was contained in a special steel transportation/storage vessel where it was being continuously bathed

with fresh water. The fresh water served two purposes: (1) flush out the brine solution, which had penetrated every element of the capsule, and (2) keep the capsule wet so that the corrosion products would

tend to stay soft and be easier to handle. Some corrosion materials can turn to a rock-hard compound

that is hard to remove, which would make refurbishment difficult. Unfortunately, in this first trip to the

Cosmosphere, the capsule could not be viewed directly because it was inside the transportation/storage

vessel and there were no viewing ports. The drawings for the steel transportation/storage vessel were

studied to see what physical constraints might be placed upon measuring with CT and to see how other

inspections could be made. Because the capsule was housed in the closed container, no direct visual

evaluation was made at this time. The rest of the trip was made to Hill AFB where a large CT system

was available for evaluation. The Navy's CT system was unavailable for inspection at this time. At Hill

AFB, it was discovered that several physical limitations did exist. First, the storage vessel of the capsule

had external lifting and tie-down structures that exceeded the maximum allowable diameter of the CT

systems by several centimeters. Second, the door to the facility, which was designed for their trucks and

loads, was nearly 0.5 meter too short for the storage vessel to go through. These two limitations would

force the additional handling complications of opening the storage vessel and transferring the capsule to

4
theinsideof thebuildingandthenintoanotherholdingtankthatwaslessthen2.44metersindiameter

andabout2.5meterstallwhereit couldbesubmergedin freshwateragain.

Reality

We learned after these initial visits in subsequent talks with people who had been present during the

recovery of the capsule that the TPS heat shield was not a phenolic TPS material. Instead, the first two

flights had a beryllium heat shield for its TPS, which in the case of Liberty Bell 7 had completely corroded and was not recovered with the capsule. This fact, added to the complications of doing a CT scan

at Hill AFB, removed most of the incentive of trying to perform CT and ultrasonic nondestructive evaluation on the Libert3 Bell 7. The decision was made that a few individuals should visit the Cosmosphere

at the time the storage vessel was opened and make a visual inspection to determine if any NDE was

warranted.

Results of Inspection

On September l, 1999, James Lewis of JSC and Eric Madaras of LaRC visited the Cosmosphere to

be on hand for the removal of the Liberty Bell 7 capsule from its storage vessel. The storage tank was

opened at about 8:30 a.m., and the capsule was moved from the storage tank into an open viewing facility designed for the refurbishment of the capsule and simultaneous public viewing. The move took

approximately 3 hours. After that, removal and cataloging of the contents of the capsule commenced.

The external structure was in surprisingly good condition. (See fig. 3.) The black object at the bottom of the capsule is a skirt that provided ballast support. The heat shield would have been below the

skirt, but the heat shield was missing and had not been recovered. The bottom structures included the

Figure 3. Liber O' Bell 7 capsule being removed from its transportation/storage vessel. Photograph courtesy of

Kansas Cosmosphere and Science Center.

5
flexible skirt and various metal strips and springs, a covering that appeared to be a polymer-based material, and the capsule base behind that; all looked to be in good condition. The external covering of

the cone-shaped sides of the capsule consisted of small sheet-metal corrugated panels approximately

0.031 inch thick, which showed no signs of corrosion. Even the paint was still attached; although in

some locations, it was loose. An electronic thickness gauge indicated that the sheet metal was a consistent thickness; this implied no corrosion. The upper portion of the capsule, which was made of thick

aluminum plates, experienced significant material loss caused by corrosion. Although some areas measured full thickness of approximately 0.220 inch, most regions were less, including several areas where

the material was completely lost. Attached to these aluminum plates were large nodules of corrosion

products.

The internal structure was far from pristine. The right instrument panel was almost corroded away

with the gauges and switches sitting on the astronaut's seat but still attached to the wiring harnesses. In

addition, the forward part of the periscope pedestal and the central console were also totally corroded

away. Two cameras were recovered, but their film reels were in very poor condition. A few additional

instruments and gauges such as the "eight-bail" and the pitch, roll, and yaw gauges were lying on the

couch. The other panels seemed to still be intact. Some electronic equipment mounted on the sides of

the capsule was badly corroded. (See fig. 4.) The oxygen tank looked to be intact, whereas a helium tank

appeared to have ruptured. Many of the gauges showed signs of implosion at the glass covers. Most of

the polymer-based materials such as the seat, the harness, and the flashlight appeared to have survived

the long-term exposure of the seawater intact. All material and structural degradations were consistent

with the effects of high pressure at deep ocean depths and long exposure to salt water.

Items of historical note that were recovered on the first afternoon included the astronaut's flight

notebook, four mercury dimes, a survival knife, and the cover for the door detonation switch. (See

figs. 4, 5, and 6.) On the second day of investigation, an additional 35 mercury dimes were discovered.

Figure 4. Retrieval of astronaut's flight notebook; numerous electronic gauges, switches, and wiring harnesses are

visible. Photograph courtesy of Kansas Cosmosphere and Science Center.

6
Figure 5. One of numerous mercury dimes recovered from debris and muck at bottom of capsule that were reportedly carried on board as souvenirs to commemorate the mercury flight. Photograph courtesy of Kansas Cosmosphere and Science Center.

(a) Knife encrusted in mud and muck from bottom of capsule.

(b) Knife after renovation work.

Figure 6. Recovered survival knife reportedly left in capsule. Photographs courtesy of Kansas Cosmosphere and

Science Center.
6-0CT-1999

Figure 7. Liberty Bell 7 capsule with skin, insulation, and much of interior instrumentation removed. Video

camera image courtesy of Kansas Cosmosphere and Science Center.

Refurbishment of the capsule is now well underway. Most of the internal components have been

removed and much of the skin has been taken off. (See fig. 7.) The aluminum plates on the recovery

tower were so badly corroded that they are probably beyond recovery. The small sheet-metal corrugated

panels for the skin were indeed in excellent condition.

Concluding Remarks

The condition of the Libert3' Bell 7 capsule and its contents was consistent with long-term exposure

to salt water and high pressures at the bottom of the ocean. No identifiable items were found that

appeared to have any scientific value. At this time, no further nondestructive evaluation appears to be

justified.

Bibliography

Discovery Communications Inc. Home Page. http://www.discovery.com Accessed 10-05-99.

Liberating the Liberty Bell 7. hltp://www.dis¢overv.com/exp/libertvbell7flibertvbell7.html Accessed 10-05-99.

Kansas Cosmosphere and Space Center Home Page. http://www.cosmo.orgl Accessed 10-05-99.

Liberty Bell 7. http://www.cosmo.org/libertybell7.html Accessed 10-05-99

8

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December 1999 Technical Memorandum

4. TITLE AND SUBTITLE

Liberty Bell 7 Recovery Evaluation and Nondestructive Testing

6. AUTHOR(S)

Eric I. Madaras and William L. Smith

17. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

NASA Langley Research Center

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NASA/TM-1999-209824

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13, ABSTRACT (Maximum 200 words)

An inspection of the Mercury capsule, Liherty Bell 7, and its contents was made on September 1 and 2, 1999. The

condition of the capsule and its contents was consistent with long-term exposure to salt water and high pressures at

the bottom of the ocean. Many of the metallic materials suffered corrosion, whereas the polymer-based materials

seem to have survived remarkably well. No identifiable items or structures were found that appeared to have any

scientific value. At this time, no further nondestructive evaluation appears to bc justified.

[14. SUBJECT TERMS

Mercury Program; Liberty Bell 7; Nondestructive evaluation

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