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Suits, Michael W.

Publications and source records attributed to Suits, Michael W..

8 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2006

Nondestructive Evaluation of the Gimbal Joint Flowliner Slots in the Space Shuttle Main Propulsion System Hydrogen Feedline

Fatigue cracks were discovered in the STS-112 Liquid Hydrogen Feedline flowliners in 2002. This led to a development program aimed at providing nondestructive evaluation methods and techniques to verify the existence of these types of cracks in oval shaped slots cut into the ends of the feedlines above the bellows joints. These slots were used to improve flow dynamics and to facilitate cleaning in the bellow joint region. These types of fatigue cracks posed a possible metal debris ingestion threat for the Space Shuttle Main Engines, which attached to these particular joints. Results of this program produced three reliable inspection techniques utilizing the imaging of replisets with a Scanning Electron microscope, eddy current, and ultrasound. The program developed unique probes and fixtures and in the case of eddy current and ultrasound, provided qualification and certification of the particular techniques by various Design of Experiments and Probability of Detection studies utilizing multiple inspectors.

Suits, Michael W.↗
NASA NTRS2003

Fatigue Crack and Porosity Measurement in Composite Materials by Thermographic and Ultrasonic Methods

Contents include the following: 1. Purpose. Detect thermo-mechanically induced intra-ply fatigue microcracking and manufactured porosity in unlined composite pressure vessels. 2. Defect descriptions. Porosity, microcracking. 3. Thermography. Overview of technique. Strengths and Weaknesses. Examples of its use for porosity detection. 4. Resonant ultrasound spectroscopy. Overview of technique. Strengths and Weaknesses. Examples of its use for microcracking detection. Conclusions.

Walker, James L.↗
NASA NTRS2003

Microcrack Quantification in Composite Materials by a Neural Network Analysis of Ultrasound Spectral Data

Intra-ply microcracking in unlined composite pressure vessels can be very troublesome to detect and when linked through the thickness can provide leak paths that may hinder mission success. The leaks may lead to loss of pressure/propellant, increased risk of explosion and possible cryo-pumping into air pockets within the laminate. Ultrasonic techniques have been shown capable of detecting the presence of microcracking and in this work they are used to quantify the level of microcracking. Resonance ultrasound methods are utilized with artificial neural networks to build a microcrack prediction/measurement tool. Two networks are presented, one unsupervised to provide a qualitative measure of microcracking and one supervised which provides a quantitative assessment of the level of microcracking. The resonant ultrasound spectroscopic method is made sensitive to microcracking by tuning the input spectrum to the higher frequency (shorter wavelength) components allowing more significant interaction with the defects. This interaction causes the spectral characteristics to shift toward lower amplitudes at the higher frequencies. As the density of the defects increases more interactions occur and more drastic amplitude changes are observed. Preliminary experiments to quantify the level of microcracking induced in graphite/epoxy composite samples through a combination of tensile loading and cryogenic temperatures are presented. Both unsupervised (Kohonen) and supervised (radial basis function) artificial neural networks are presented to determine the measurable effect on the resonance spectrum of the ultrasonic data taken from the samples.

Walker, James L.↗
NASA NTRS2002

Fatigue Crack Measurement in Composite Materials by Ultrasonic Methods

The nondestructive detection of intra-ply microcracking in unlined pressure vessels fabricated from composite materials is critical to ensuring mission success. Microcracking in composite structures due to combined fatigue and cryogenic thermal loading can be very troublesome to detect in-service and when it begins to link through the thickness can cause leakage and failure of the structure. These leaks may lead to loss of pressure/propellant, increased risk of explosion and possible cryo-pumping. The work presented herein develops a method and an instrument to locate and measure intraply fatigue cracking through the thickness of laminated composite material by means of correlation with ultrasonic resonance. Resonant ultrasound spectroscopy provides measurements which are, sensitive to both the microscopic and macroscopic properties of an object. Elastic moduli, acoustic attenuation, and geometry can all be probed. The approach is based on the premise of half-wavelength resonance. The method injects a broadband ultrasonic wave into the test structure using a swept frequency technique. This method provides dramatically increased energy input into the test article, as compared to conventional spike pulsed ultrasonics. This relative energy increase improves the ability to measure finer details in the materials character, such as micro-cracking and porosity. As the micro-crack density increases, more interactions occur with the higher frequency (small wavelength) components of the signal train causing the spectrum to shift toward lower frequencies. Preliminary experiments have verified a measurable effect on the resonance spectrum of the ultrasonic data to detect microcracking. Methods involving self organizing neural networks and other clustering algorithms show that the resonance ultrasound signatures from composites vary with the degree of microcracking and can be separated and identified.

Walker, James L.↗
NASA NTRS2002

Fatigue Crack and Porosity Measurement in Composite Materials by Thermographic and Ultrasonic Methods

Many nondestructive methods exist for the detection of localized material anomalies in an otherwise good composite structure. The problem arises when the material system as a whole has degraded during service or was improperly manufactured. Porosity and intra-ply microcracking are two such conditions that in unlined composite pressure vessels can be very troublesome to detect and when linked through the thickness can be critical to mission success. These leak paths may lead to loss of pressure/propellant, increased risk of explosion and possible cryo-pumping. Research sought nondestructive methods for quantifying porosity and microcracking in composite tankage. Both thermographic and resonance ultrasound methods have been utilized with artificial neural network and statistical approaches to analyze the data. Resonant ultrasound spectroscopy provides measurements, which are sensitive to fine details in the materials character, such as micro-cracking and porosity. Here, the higher frequency (shorter wavelength) components of the signal train provide more significant interaction with the defects causing the spectral characteristics to shift toward lower amplitudes at the higher frequencies. As the density of the defects increases more interactions occur and more drastic amplitude changes are observed. From a thermal perspective, the higher the defect density the lower the through thickness thermal diffusivity will be. Utilizing a point heat source, and thermographically recording the heat profile with time, diffusivity calculations can be made which in turn can be related to the relative quality of the material. Preliminary experiments to verify the measurable effect on the resonance spectrum of the ultrasonic data to detect microcracking and for porosity detection thermographically are presented. Methods involving supervised and unsupervised artificial neural networks as well as other clustering algorithms are developed for signal identification.

Walker, James L.↗
NASA NTRS1999

Nondestructive Evaluation of the Friction Weld Process on 2195/2219 Grade Aluminum

In 1996, NASA's Marshall Space Flight Center began an ambitious program designed to find alternative methods of repairing conventional TIG (Tungsten Inert Gas) welds and VPPA (Variable Polarity Plasma Arc) welds on the Space Shuttle External Tank without producing additional heat-related anomalies or conditions. Therefore, a relatively new method, invented by The Welding Institute (TWI) in Cambridge, England, called Friction Stir Welding (FSW), was investigated for use in this application, as well as being used potentially as an initial weld process. As with the conventional repair welding processes, nondestructive evaluation (NDE) plays a crucial role in the verification of these repairs. Since it was feared that conventional NDE might have trouble with this type of weld structure (due to shape of nugget, grain structure, etc.) it was imperative that a complete study be performed to address the adequacy of the NDE process. This paper summarizes that process.

Suits, Michael W.↗
NASA NTRS1993

Ultrasonic inspection of a diffusion-bonded platelet rocket chamber liner

An ultrasonic inspection technique, which applies pulse-echo technology for examining the rocket chamber's liner-to-jacket interface was developed, which makes it possible to characterize disbonded layers in intimate contact. The method was used to inspect a simulated flat-geometry rocket chamber liner structure with debonded liner layers and to validate the use of boron nitride powder as a flaw introduction technique.

Matson, Douglas M.↗