Recent materials problems relating to catastrophic balloon failures

Balloons fabricated of thin polyethylene materials have provided relatively inexpensive and reliable scientific research platforms for approximately three decades. Reliability of the modern day balloon, as launched by the U.S.A. National Scientific Balloon Facility (NSBF), has been approximately 85%. Recent balloon failures, coupled with an increased occurrence of catastrophic failures, created grave concern over the integrity of the present balloon inventory of the U.S.A National Aeronautics and Space Administration (NASA). An investigative team was established by NASA to review the circumstances surrounding the catastrophic balloon failures, determine the cause and to make recommendations to correct the problem and to prevent its reoccurrence. The most probable cause of failure as determined by the investigation was the polyethylene balloon film, although the film had passed the established standard quality control measures of the film manufacturer. The approach, findings, and conclusions of the investigation are presented along with planned procedures to assure future quality balloon film for NASA balloons.