During manufacture of the existing External Tanks (ETs), the Thermal Protection System (TPS) foam manual spray application processes lacked the enhanced controls/procedures to ensure that defects produced were less than the critical size. Therefore the only remaining option to certify the "fly-as-is" foam is to verify ET120 tank hardware meets the new foam debris requirements. The ET project has undertaken a significant effort studying the existing "fly-as-is" TPS foam. This paper contains the findings of the study. Stadler, John H. Langley Research Center NASA/TM-2009-215917, NESC-PB-04-10, L-19752, LF99-9332
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