Gouge found on space shuttle belly

Nasa discovered a worrisome gouge on Endeavour’s belly soon after the shuttle docked with the international space station, possibly caused by ice that broke off the fuel tank a minute after lift-off.

The gouge, about 3ins square, was spotted in zoom-in photography taken by the space station crew shortly before Endeavour delivered the seven-member crew to the orbiting outpost.

“What does this mean? I don’t know at this point,” said John Shannon, chairman of the mission management team.

If the gouge was deep enough, the shuttle astronauts might have to patch it during a spacewalk, he said.

Columbia was destroyed during re-entry four years ago because of a hole in its wing, the result of a large chunk of foam insulation that broke off the external fuel tank and slammed into the wing at lift-off. Ice is heavier than foam, however, and would cause more damage to the thermal cover that protects the shuttle from the intense heat of re-entry at flight’s end.

Nasa was still rejoicing over the shuttle’s arrival at the space station yesterday and the grand entrance by Barbara Morgan, the back-up for teacher Christa McAuliffe on Challenger’s tragic mission in 1986, when engineers saw photos of the gouge. Challenger exploded just after lift-off.

Tomorrow, the astronauts will inspect the area using Endeavour’s 100ft robot arm and extension beam. Lasers on the end of the beam will gauge the exact size and depth of the gouge, Shannon says, and then engineering analyses will determine whether the damage is severe enough to warrant repairs.

The astronauts got a chance to see the damage after Mission Control sent them pictures early today.

If the gouge is deemed serious and cannot be fixed, the shuttle astronauts would have to remain at the space station. They have more than two months of supplies with them and a rescue shuttle could be launched by early October, Shannon said.

The astronauts have three methods for repairing tile damage, if necessary: they could apply black paint, screw on a protective plate, or squirt in goo.

The gouge – white against the black tiles on the underside of Endeavour – is four or five feet from the starboard main landing gear door. It appears to be the result of ice, although engineers are not positive; the damage could have been caused by a piece of foam insulation that came off the fuel tank.

Radar images show a white spray or streak coming off Endeavour 58 seconds after lift-off.

Engineers theorise that if the debris was ice, it pierced the tile and then broke up, scraping the area downwind.

“It looks like it was an ice impact to me,” Shannon said.

Even though it was an extremely hot day in Florida when Endeavour lifted off, the fuel tank was loaded with super-cold fuel, which could have allowed dangerously big chunks of ice to form on its surface.

In all, nine pieces of debris, mostly foam, came off the fuel tank during Wednesday evening’s lift-off and three were believed to have struck the shuttle. Shannon said further analysis of the photos could uncover more damage.

Commander Scott Kelly was at the controls when Endeavour performed an orbital backflip earlier in the day so the space station crew could photograph the belly and check for any damage.

The 210-mile-high backflip – which lasted nine minutes and spanned the entire Atlantic – has been standard procedure ever since the Columbia disaster, providing a rare camera view of the shuttle’s often-nicked underside.

Space station astronaut Clay Anderson videotaped the backflip, while his two Russian crewmates snapped furiously away on digital cameras equipped with high-powered zoom lenses. Nearly 300 digital pictures were beamed back to Earth.

Shortly afterward, Endeavour pulled up to the space station and parked neatly. The shuttle will remain at the outpost for at least a week.

Morgan’s entrance into the space station was dramatic, to say the least.

The former Idaho primary school teacher’s crewmates, all but one of whom floated in ahead of her, resembled paparazzi as they photographed her coming through the hatch. The station residents also captured the moment with cameras. She paused as the flashes popped, a video camera running in her right hand and sunglasses pushed up on her forehead.

Morgan briefly set aside her camera to hug the three space station residents, then took more video of the crowded outpost. She plans to use the video for educational events after the mission.