Nonlinear Dynamic Analyses of STS-1 Forward RCS Oxidizer Tank Structural Failure

At liftoff of the first Space Shuttle mission, a strong ignition overpressure pulse excited the stack. The frequency of the experienced pressure wave exceeded pre-launch predictions, and resulted in high, alternating normal accelerations along the length of the vehicle. As result of this unexpected loading, an oxidizer tank support strut in the orbiter’s forward reaction control system module failed in buckling under axial compression, which could have led to loss of the mission, crew, and vehicle. This incident is investigated in more detail using linear and nonlinear finite element analyses, complementing previous analyses with classical structural mechanics. The results of these analyses are examined to provide additional insight into the accident and to better inform future design decisions for modern space vehicle systems and structures.