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Erin Lanigan

Publications and source records attributed to Erin Lanigan.

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

NASA's Certification and Qualification Challenges for Additively Manufactured Hardware: What Is Next?

In 2021, NASA released NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems” to create qualification and certification strategies for mature metallic and non-metallic AM materials and technologies. While these standards have had an immediate impact on the additive manufacturing (AM) industry, there remain many challenges that have yet to be overcome. NASA and its partners in academia and industry are working together to proactively address these issues. One of the most critical needs is a Probabilistic Damage Tolerance Assessment (PDTA) approach, which includes the development of computational modeling, understanding the “effect of defects”, and the implementation of in-situ process monitoring and inspection techniques.

Will Tilson↗
NASA NTRSDate not supplied

Analyzing the Subjectivity of Hole-Type Image Quality Indicators for Radiography

Hole-type penetrameters used as image quality indicators (IQIs) for radiography have an inherent degree of subjectivity to their interpretation. The 1T (one times the thickness of the penetrameter) hole is so small, it can be difficult to distinguish from noise. It is suspected that an operator’s knowledge of the true location of the 1T hole may subconsciously influence a false positive identification of the 1T hole when in fact it cannot be discerned. In the case of computed radiography (CR), the size of the phosphor particles may lead to a noise pattern with features on the scale of the 1T hole. Per NASA-STD-5009, the 1T hole must be detected in order to achieve adequate sensitivity. This is based on the historical understanding that this sensitivity will enable detection of the minimum detectable flaw sizes listed in the standard. It’s important to understand if 1T sensitivity is being achieved, and the associated risk if not. This study sought to determine the true detectability of 1T-sized holes in aluminum and Inconel by creating and inspecting a set of penetrameters with randomly placed holes. Enough holes and vacant zones were created to enable a full probability of detection study with 90% detectability, 95% confidence. Testing is ongoing, but preliminary results have shown poor detectability. The detection rate is slightly better for Inconel than aluminum, slightly better using a micro-focus vs. mini-focus tube, and definitively better for film than CR. One of the key questions of this study is whether historical requirements for film are applicable for CR, and these initial findings suggest they may not be. There is also a requirement in the NASA standard for the minimum contrast-to-noise ratio of the hole. The results have shown that this numerical threshold does not correlate well with visual detection. This raises questions about the true nature of detection, in an age of image processing vs. human judgement. As the results indicate that the detection of 1T holes is unreliable, the next challenge will be determining what sensitivity is really achieved, and what is needed.

Erin Lanigan↗
NASA NTRSDate not supplied

Convolutional Autoencoder for Defect Detection in Additive Manufacturing

The core idea behind using machine learning (ML) for defect detection is that it can be used to detect flaws as they are being formed in an AM part. As the part is being made, a near-infrared (NIR) sensor records each layer and creates an image of the entire build layer. These images, usually thousands, can be compiled into a ‘3D’ array of the entire part. ML tools, such as a convolutional autoencoder (CAE) can go through these images and highlight potential anomalous regions of your part.

In-Situ Monitoring↗
NASA NTRSDate not supplied

NASA’S Current Efforts and Applications of NDE to Improve Space Flight Safety

National Aeronautics and Space Administration (NASA) continues to push the boundary of manned flight. Current mission profiles include flights to the moon and mars. Many of these missions require advance manufacturing and planned off planet resource utilization. As NASA continues to develop highly advance materials and manufacturing techniques to meet these mission profiles, inspection of these increasingly complex parts has had to evolve as well. Additive manufacturing is coming to the forefront as a primary manufacturing technique but offers unique challenges when inspection and certification are required. NASA has been working diligently to be a leader in developing and utilizing inspection techniques capable of inspecting these highly advanced parts. Additionally additive manufacturing techniques can also be used to build parts in space and provides a vehicle for in-situ resource utilization for off world missions. As NASA and its commercial crew partners move forward inspection techniques will need to continue to advance to ensure safe manned space flight. In this talk NASA will highlight many of the advanced nondestructive evaluation efforts going on across the agency. As well as highlights for points of infusion for helping NASA meet it’s future missions.

NDE↗
NASA NTRSDate not supplied

Three-Dimensional Reconstruction of Defects and Structures in Additively Manufactured Parts with Automated Serial Sectioning

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with complex components for space flight applications. Laser powderbed fusion (L-PBF) is a commonly used AM technology due to the ability to produce complex parts with fine feature resolution in a wide variety of alloys and applications. L-PBF, like many other manufacturing processes, can produce minor flaws in parts when in nominal operation as well as process-escape defects when process abnormalities occur. The effects of the flaws and methods of detecting the flaws are a subject of interest to understand the difficulties in detecting these flaws with current technology and how much risk the flaws or defects pose to potential flight parts. Using a RoboMet.3D automated serial sectioning system, seeded defects as well as minor process flaws can be imaged and reconstructed in three dimensions to compare to non-destructive evaluation (NDE) techniques, such as x-ray computed tomography (CT), neutron CT, and in-situ monitoring. The RoboMet automates the metallography process by automatically grinding, polishing, and imaging samples in a single system and providing the control data for NDE comparisons to know the real size of defects built into coupons. These comparisons provide an understanding behind the technological limitations of the NDE techniques for different alloys. The same serial sectioning methods have also been utilized to characterize the surfaces of parts to reconstruct the surfaces and take measurements of internal features not easily examined with non-destructive methods. Using the RoboMet, fine lattice structures built with L-PBF have been characterized to determine the actual thicknesses of struts and density of the lattice structures. These structures have been used as finer build supports for the L-PBF process, designs for fine catalysts, and other design considerations for small components. The RoboMet data helps to inform the modeling and design efforts around these fine components.

additive manufacturing↗