Engineering topics

Bodis, James R.

Publications and source records attributed to Bodis, James R..

12 records

NASA NTRS2012

Turbine Engine Disk Rotor Health Monitoring Assessment Using Spin Tests Data

Detecting rotating engine component malfunctions and structural anomalies is increasingly becoming a crucial key feature that will help boost safety and lower maintenance cost. However, achievement of such technology, which can be referred to as a health monitoring remains somewhat challenging to implement. This is mostly due to presence of scattered loading conditions, crack sizes, component geometry and material properties that hinders the simplicity of imposing such application. Different approaches are being considered to assist in developing other means of health monitoring or nondestructive techniques to detect hidden flaws and mini cracks before any catastrophic events occur. These methods extend further to assess material discontinuities and other defects that have matured to the level where a failure is very likely. This paper is focused on presenting data obtained from spin test experiments of a turbine engine like rotor disk and their correlation to the development of a structural health monitoring and fault detection system. The data collected includes blade tip clearance, blade tip timing measurements and shaft displacements. The experimental results are collected at rotational speeds up to 10,000 Rpm and tests are conducted at the NASA Glenn Research Center s Rotordynamics Laboratory via a high precision spin system. Additionally, this study offers a closer glance at a selective online evaluation of a rotating disk using advanced capacitive, microwave and eddy current sensor technology.

Abdul-Aziz, Ali↗

NASA NTRS2005

Nondestructive Evaluation Tests Performed on Space Shuttle Leading- Edge Materials Subjected to Impact

In support of the space shuttle Return To Flight efforts at the NASA Glenn Research Center, a series of nondestructive evaluation (NDE) tests were performed on reinforced carbon/carbon (RCC) composite panels subjected to ballistic foam impact. The impact tests were conducted to refine and verify analytical models of an external tank foam strike on the space shuttle leading edge. The NDE tests were conducted to quantify the size and location of the resulting damage zone as well as to identify hidden damage.

Roth, Don J.↗

NASA NTRS2001

High-Frequency Focused Water-Coupled Ultrasound Used for Three-Dimensional Surface Depression Profiling

To interface with other solids, many surfaces are engineered via methods such as plating, coating, and machining to produce a functional surface ensuring successful end products. In addition, subsurface properties such as hardness, residual stress, deformation, chemical composition, and microstructure are often linked to surface characteristics. Surface topography, therefore, contains the signatures of the surface and possibly links to volumetric properties, and as a result serves as a vital link between surface design, manufacturing, and performance. Hence, surface topography can be used to diagnose, monitor, and control fabrication methods. At the NASA Glenn Research Center, the measurement of surface topography is important in developing high-temperature structural materials and for profiling the surface changes of materials during microgravity combustion experiments. A prior study demonstrated that focused air-coupled ultrasound at 1 MHz could profile surfaces with a 25-m depth resolution and a 400-m lateral resolution over a 1.4-mm depth range. In this work, we address the question of whether higher frequency focused water-coupled ultrasound can improve on these specifications. To this end, we employed 10- and 25-MHz focused ultrasonic transducers in the water-coupled mode. The surface profile results seen in this investigation for 25-MHz water-coupled ultrasound, in comparison to those for 1-MHz air-coupled ultrasound, represent an 8 times improvement in depth resolution (3 vs. 25 m seen in practice), an improvement of at least 2 times in lateral resolution (180 vs. 400 m calculated and observed in practice), and an improvement in vertical depth range of 4 times (calculated).

Roth, Don J.↗

NASA NTRS2000

New Technology-Large-Area Three- Dimensional Surface Profiling Using Only Focused Air-Coupled Ultrasound-Given 1999 R&D 100 Award

Surface topography, which significantly affects the performance of many industrial components, is normally measured with diamond-tip profilometry over small areas or with optical scattering methods over larger areas. To develop air-coupled surface profilometry, the NASA Glenn Research Center at Lewis Field initiated a Space Act Agreement with Sonix, Inc., through two Glenn programs, the Advanced High Temperature Engine Materials Program (HITEMP) and COMMTECH. The work resulted in quantitative surface topography profiles obtained using only high-frequency, focused ultrasonic pulses in air. The method is nondestructive, noninvasive, and noncontact, and it does not require light-reflective surfaces. Air surface profiling may be desirable when diamond-tip or laserbased methods are impractical, such as over large areas, when a significant depth range is required, or for curved surfaces. When the configuration is optimized, the method is reasonably rapid and all the quantitative analysis facilities are online, including two- and three-dimensional visualization, extreme value filtering (for faulty data), and leveling.

Roth, Don J.↗

NASA NTRS1999

Using High Frequency Focused Water-Coupled Ultrasound for 3-D Surface Depression Profiling

Surface topography is an important variable in the performance of many industrial components and is normally measured with diamond-tip profilometry over a small area or using optical scattering methods for larger area measurement. A prior study was performed demonstrating that focused air-coupled ultrasound at 1 MHz was capable of profiling surfaces with 25 micron depth resolution and 400 micron lateral resolution over a 1.4 mm depth range. In this article, the question of whether higher-frequency focused water-coupled ultrasound can improve on these specifications is addressed. 10 and 25 MHz focused ultrasonic transducers were employed in the water-coupled mode. Time-of-flight images of the sample surface were acquired and converted to depth / surface profile images using the simple relation (d = V*t/2) between distance (d), time-of-flight (t), and the velocity of sound in water (V). Results are compared for the two frequencies used and with those from the 1 MHz air-coupled configuration.

Roth, Don J.↗

NASA NTRS1999

3-D Surface Depression Profiling Using High Frequency Focused Air-Coupled Ultrasonic Pulses

Surface topography is an important variable in the performance of many industrial components and is normally measured with diamond-tip profilometry over a small area or using optical scattering methods for larger area measurement. This article shows quantitative surface topography profiles as obtained using only high-frequency focused air-coupled ultrasonic pulses. The profiles were obtained using a profiling system developed by NASA Glenn Research Center and Sonix, Inc (via a formal cooperative agreement). (The air transducers are available as off-the-shelf items from several companies.) The method is simple and reproducible because it relies mainly on knowledge and constancy of the sound velocity through the air. The air transducer is scanned across the surface and sends pulses to the sample surface where they are reflected back from the surface along the same path as the incident wave. Time-of-flight images of the sample surface are acquired and converted to depth/surface profile images using the simple relation (d = V*t/2) between distance (d), time-of-flight (t), and the velocity of sound in air (V). The system has the ability to resolve surface depression variations as small as 25 microns, is useable over a 1.4 mm vertical depth range, and can profile large areas only limited by the scan limits of the particular ultrasonic system. (Best-case depth resolution is 0.25 microns which may be achievable with improved isolation from vibration and air currents.) The method using an optimized configuration is reasonably rapid and has all quantitative analysis facilities on-line including 2-D and 3-D visualization capability, extreme value filtering (for faulty data), and leveling capability. Air-coupled surface profilometry is applicable to plate-like and curved samples. In this article, results are shown for several proof-of-concept samples, plastic samples burned in microgravity on the STS-54 space shuttle mission, and a partially-coated cylindrical ceramic composite sample. Impressive results were obtained for all samples when compared with diamond-tip profiles and measurements from micrometers. The method is completely nondestructive, noninvasive, non-contact and does not require light-reflective surfaces.

Roth, Don J.↗

NASA NTRS1999

Novel Method Used to Inspect Curved and Tubular Structural Materials

At the NASA Lewis Research Center, a technique for the ultrasonic characterization of plates has been extended to tubes and to curved structures in general. In this technique, one performs measurements that yield a thickness-independent value of the local through-the-thickness speed of sound in a specimen. From such measurements at numerous locations across the specimen, one can construct a map of velocity as a function of location. The gradients of velocity indicated by such a map indicate local through-the-thickness-averaged microstructural parameters that affect the speed of sound. Such parameters include the pore volume fraction, mass density, fiber volume fraction (in the case of a composite material), and chemical composition. Apparatus was designed to apply the technique to tubular and other curved specimens.

Roth, Don J.↗

NASA NTRS1998

A Novel Ultrasonic Method for Characterizing Microstructural Gradients in Tubular Structures

Ultrasonic velocity and time-of-flight (TOF) imaging that uses back surface reflections to gage volumetric material quality is highly suited for quantitative characterization of microstructural gradients including those due to pore fraction, density, fiber fraction, and chemical composition variations. However, a weakness of conventional pulse echo ultrasonic velocity and TOF imaging is that the image shows the effects of thickness as well as microstructural variations, unless the part is uniformly thick. This limits this imaging method's usefulness in practical applications. Prior studies have described a pulse echo TOF based ultrasonic imaging method that requires using a single transducer in combination with a reflector plate placed behind samples which, eliminates the effect of thickness variation in the image. In those studies, this method was successful at isolating ultrasonic variations due to material in plate like samples of silicon nitride, metal matrix composite, and polymer matrix composite. In this study, the method is engineered for inspection of more complex shaped structures- those having (hollow) tubular or curved geometry. The experimental inspection technique and results are described as applied to a polymer matrix composite "proof of concept" tube that contains machined patches of various depths and an as manufactured monolithic silicon nitride ceramic tube that might be used in "real world" applications.

Roth, Don J.↗

NASA NTRS1998

Scaling up the Single Transducer Thickness-Independent Ultrasonic Imaging Method for Accurate Characterization of Microstructural Gradients in Monolithic and Composite Tubular Structures

Ultrasonic velocity/time-of-flight imaging that uses back surface reflections to gauge volumetric material quality is highly suited for quantitative characterization of microstructural gradients including those due to pore fraction, density, fiber fraction, and chemical composition variations. However, a weakness of conventional pulse-echo ultrasonic velocity/time-of-flight imaging is that the image shows the effects of thickness as well as microstructural variations unless the part is uniformly thick. This limits this imaging method's usefulness in practical applications. Prior studies have described a pulse-echo time-of-flight-based ultrasonic imaging method that requires using a single transducer in combination with a reflector plate placed behind samples that eliminates the effect of thickness variation in the image. In those studies, this method was successful at isolating ultrasonic variations due to material microstructure in plate-like samples of silicon nitride, metal matrix composite, and polymer matrix composite. In this study, the method is engineered for inspection of more complex-shaped structures-those having (hollow) tubular/curved geometry. The experimental inspection technique and results are described as applied to (1) monolithic mullite ceramic and polymer matrix composite 'proof-of-concept' tubular structures that contain machined patches of various depths and (2) as-manufactured monolithic silicon nitride ceramic and silicon carbide/silicon carbide composite tubular structures that might be used in 'real world' applications.

Roth, Don J.↗

NASA NTRS1996

Commercial Implementation of Ultrasonic Velocity Imaging Methods via Cooperative Agreement Between NASA Lewis Research Center and Sonix, Inc.

This article describes the commercial implementation of ultrasonic velocity imaging methods developed and refined at NASA Lewis Research Center on the Sonix c-scan inspection system. Two velocity imaging methods were implemented: thickness-based and non-thickness-based reflector plate methods. The article demonstrates capabilities of the commercial implementation and gives the detailed operating procedures required for Sonix customers to achieve optimum velocity imaging results. This commercial implementation of velocity imaging provides a 100x speed increase in scanning and processing over the lab-based methods developed at LeRC. The significance of this cooperative effort is that the aerospace and other materials development-intensive industries which use extensive ultrasonic inspection for process control and failure analysis will now have an alternative, highly accurate imaging method commercially available.

Roth, Don J.↗

NASA NTRS1995

Thermographic imaging for high-temperature composite materials: A defect detection study

The ability of a thermographic imaging technique for detecting flat-bottom hole defects of various diameters and depths was evaluated in four composite systems (two types of ceramic matrix composites, one metal matrix composite, and one polymer matrix composite) of interest as high-temperature structural materials. The holes ranged from 1 to 13 mm in diameter and 0.1 to 2.5 mm in depth in samples approximately 2-3 mm thick. The thermographic imaging system utilized a scanning mirror optical system and infrared (IR) focusing lens in conjunction with a mercury cadmium telluride infrared detector element to obtain high resolution infrared images. High intensity flash lamps located on the same side as the infrared camera were used to heat the samples. After heating, up to 30 images were sequentially acquired at 70-150 msec intervals. Limits of detectability based on depth and diameter of the flat-bottom holes were defined for each composite material. Ultrasonic and radiographic images of the samples were obtained and compared with the thermographic images.

Roth, Don J.↗

NASA NTRS1994

An NDE Approach for Characterizing Quality Problems in Polymer Matrix Composites

Polymer matrix composite (PMC) materials are periodically identified appearing optically uniform but containing a higher than normal level of global nonuniformity as indicated from preliminary ultrasonic scanning. One such panel was thoroughly examined by nondestructive (NDE) and destructive methods to quantitatively characterize the nonuniformity. The NDE analysis of the panel was complicated by the fact that the panel was not uniformly thick. Mapping of ultrasonic velocity across a region of the panel in conjunction with an error analysis was necessary to (1) characterize properly the porosity gradient that was discovered during destructive analyses and (2) account for the thickness variation effects. Based on this study, a plan for future NDE characterization of PMC's is presented to the PMC community.

Roth, Don J.↗