Brake Failure from Residual Magnetism in the Mars Exploration Rover Lander Petal Actuator

In January 2004, two Mars Exploration Rover spacecraft arrived at Mars. Each safely delivered an identical rover to the Martian surface in a tetrahedral lander encased in airbags. Upon landing, the airbags deflated and three Lander Petal Actuators opened the three deployable Lander side petals enabling the rover to exit the Lander. Approximately nine weeks prior to the scheduled launch of the first spacecraft, one of these mission-critical Lander Petal Actuators exhibited a brake stuck-open failure during its final flight stow at Kennedy Space Center. Residual magnetism was the definitive conclusion from the failure investigation. Although residual magnetism was recognized as an issue in the design, the lack of an appropriately specified lower bound on brake drop-out voltage inhibited the discovery of this problem earlier in the program. In addition, the brakes had more unit-to-unit variation in drop-out voltage than expected, likely due to a larger than expected variation in the magnetic properties of the 15-5 PH stainless steel brake plates. Failure analysis and subsequent rework of two other Lander Petal Actuators with marginal brakes was completed in three weeks, causing no impact to the launch date.