A stress index model for balloon design

The modern day scientific research balloon has historically maintained an approximate 85% success rate as launched by the USA National Scientific Balloon Facility (NSBF). Failures were across all operational phases and modes. Balloons fabricated after 1980 have met with less favorable results with catastrophic failures on ascent becoming the principle failure mode. In 1983, the USA National Aeronautics and Space Administration (NASA) conducted an intensive investigation to identify the possible causes for these failures. Although the most probable cause was identified as the balloon material, additional contributing factors were identified. One of these factors, balloon stress, was calculated using a stress equation defining only the total required thickness for launch. No model existed to predict the stress distribution in an ascending balloon. Early in 1984, NASA began the development of a stress index model to establish the relative stress magnitudes at any altitude. Studies were conducted applying this model to several hundred balloon flights. The study indicated a strong correlation between stress levels, failure rates, and the point of maximum stress coinciding with observed failure locations. In January 1985, NASA instituted a stress index design and flight specification that all NASA balloons must meet. The details and results of this work are presented.