The Columbia Accident Investigation Board had some thoughts to offer on that.
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Possible emergency procedures
The CAIB determined that a rescue mission, though risky, might have been possible provided NASA management had taken action soon enough.[48][49] They stated that had NASA management acted in time, two possible contingency procedures were available: a rescue mission by shuttle Atlantis, and an emergency spacewalk to attempt repairs to the left wing thermal protection.
Normally a rescue mission is not possible, due to the time required to prepare a shuttle for launch, and the limited consumables (power, water, air) of an orbiting shuttle. However, Atlantis was well along in processing for a planned March 1 launch on STS-114, and Columbia carried an unusually large quantity of consumables due to an Extended Duration Orbiter package. The CAIB determined that this would have allowed Columbia to stay in orbit until flight day 30 (February 15). NASA investigators determined that Atlantis processing could have been expedited with no skipped safety checks for a February 10 launch. Hence if nothing went wrong there was a five-day overlap for a possible rescue. As mission control could deorbit an empty shuttle but could not control the orbiter’s reentry and landing, it would likely have sent Columbia into the Pacific Ocean;[48] NASA later developed the Remote Control Orbiter system to permit mission control to land a shuttle. Docking at the International Space Station for use as a safe haven while awaiting rescue (or to use the Soyuz to systematically ferry the crew to safety) would have been impossible due to the different orbital inclination of both vehicles.
NASA investigators determined on-orbit repair by the shuttle astronauts was possible but risky, primarily due to the uncertain resiliency of the repair using available materials.[48][49] Columbia did not carry the Canadarm, or Remote Manipulator System, which would normally be used for camera inspection or transporting a spacewalking astronaut to the wing. Therefore an unusual emergency extra-vehicular activity (EVA) would have been required. While there was no astronaut EVA training for maneuvering to the wing, astronauts are always prepared for a similarly difficult emergency EVA to close the external tank umbilical doors located on the orbiter underside, which is necessary for reentry. Similar methods could have reached the shuttle left wing for inspection or repair.[48]
For the repair, the CAIB determined the astronauts would have to use tools and small pieces of titanium, or other metal, scavenged from the crew cabin. These metals would help protect the wing structure and would be held in place during re-entry by a water-filled bag that had turned into ice in the cold of space. The ice and metal would help restore wing leading edge geometry, preventing a turbulent airflow over the wing and therefore keeping heating and burn-through levels low enough for the crew to survive re-entry and bail out before landing. Since the NASA team could not verify that the repairs would survive even a modified re-entry, the rescue option had a considerably higher chance of bringing Columbia’s crew back alive.[48]
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Note that NASA not only didn’t ask for satellite imagery of the tiles, at a time when a rescue mission might have been possible, but intervened to prevent its own engineers from obtaining such imagery from the Department of Defense.
[QUOTE=Wikipedia]
In a risk-management scenario similar to the Challenger disaster, NASA management failed to recognize the relevance of engineering concerns for safety for imaging to inspect possible damage, and failed to respond to engineer requests about the status of astronaut inspection of the left wing. Engineers made three separate requests for Department of Defense (DOD) imaging of the shuttle in orbit to more precisely determine damage. While the images were not guaranteed to show the damage, the capability existed for imaging of sufficient resolution to provide meaningful examination. NASA management did not honor the requests and in some cases intervened to stop the DOD from assisting.[11]
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