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From what I've read about the change in foam. It was a move to keep the happy with the green weenies. And it sounds like they sacrificed the strength and integrity of the insulation in favor of being PC. Which to me is a criminal act. As for the last possible moment of aborting, I'm not sure of the specific altitude, but I do know that depending on where they are in the lauhc phase they have several airports around the world where they can land if they have to punch off the external fuel tank before they achieve orbit. Off the top of my head they emergency landing sites are in Spain, Australia, Hunter Army Airfield in Savannah, Ga., and of course Edwards AFB and right there at KSC. As for the flight safety issues, IMHO, with the yearly reduction in the NASA budget, I hink that the safety guys just kept dumbing down the bar for what was "unacceptable risk" in operating the Shuttle Program.

As for the last possible moment of aborting, I'm not sure of the specific altitude, but I do know that depending on where they are in the launch phase they have several airports around the world where they can land if they have to punch off the external fuel tank before they achieve orbit.

I think one aditional problem would be, How much time do you have to make the decision to abort the climb to orbit? If you are un-aware of damage during boost, Why would you abort the climb? Once on orbit you are committed to a re-entry. Sort of a catch-22.