Engineering topics

Walker, James L.

Publications and source records attributed to Walker, James L..

At least 19 records

NASA NTRS2014

Nondestructive Evaluation of Additive Manufacturing State-of-the-Discipline Report

This report summarizes the National Aeronautics and Space Administrations (NASA) state of the art of nondestructive evaluation (NDE) for additive manufacturing (AM), or "3-D printed", hardware. NASA's unique need for highly customized spacecraft and instrumentation is suited for AM, which offers a compelling alternative to traditional subtractive manufacturing approaches. The Agency has an opportunity to push the envelope on how this technology is used in zero gravity, an enable in-space manufacturing of flight spares and replacement hardware crucial for long-duration, manned missions to Mars. The Agency is leveraging AM technology developed internally and by industry, academia, and other government agencies for its unique needs. Recent technical interchange meetings and workshops attended by NASA have identified NDE as a universal need for all aspects of additive manufacturing. The impact of NDE on AM is cross cutting and spans materials, processing quality assurance, testing and modeling disciplines. Appropriate NDE methods are needed before, during, and after the AM production process.

Waller, Jess M.↗

NASA NTRS2013

Damage Tolerance Assessment Branch

The Damage Tolerance Assessment Branch evaluates the ability of a structure to perform reliably throughout its service life in the presence of a defect, crack, or other form of damage. Such assessment is fundamental to the use of structural materials and requires an integral blend of materials engineering, fracture testing and analysis, and nondestructive evaluation. The vision of the Branch is to increase the safety of manned space flight by improving the fracture control and the associated nondestructive evaluation processes through development and application of standards, guidelines, advanced test and analytical methods. The Branch also strives to assist and solve non-aerospace related NDE and damage tolerance problems, providing consultation, prototyping and inspection services.

Walker, James L.↗

NASA NTRS2011

High-Fidelity Modeling for Health Monitoring in Honeycomb Sandwich Structures

High-Fidelity Model of the sandwich composite structure with real geometry is reported. The model includes two composite facesheets, honeycomb core, piezoelectric actuator/sensors, adhesive layers, and the impactor. The novel feature of the model is that it includes modeling of the impact and wave propagation in the structure before and after the impact. Results of modeling of the wave propagation, impact, and damage detection in sandwich honeycomb plates using piezoelectric actuator/sensor scheme are reported. The results of the simulations are compared with the experimental results. It is shown that the model is suitable for analysis of the physics of failure due to the impact and for testing structural health monitoring schemes based on guided wave propagation.

Luchinsky, Dimitry G.↗

NASA NTRS2010

Acoustic Emission Measurement with Fiber Bragg Gratings for Structure Health Monitoring

Structural Health monitoring (SHM) is a way of detecting and assessing damage to large scale structures. Sensors used in SHM for aerospace structures provide real time data on new and propagating damage. One type of sensor that is typically used is an acoustic emission (AE) sensor that detects the acoustic emissions given off from a material cracking or breaking. The use of fiber Bragg grating (FBG) sensors to provide acoustic emission data for damage detection is studied. In this research, FBG sensors are used to detect acoustic emissions of a material during a tensile test. FBG sensors were placed as a strain sensor (oriented parallel to applied force) and as an AE sensor (oriented perpendicular to applied force). A traditional AE transducer was used to collect AE data to compare with the FBG data. Preliminary results show that AE with FBGs can be a viable alternative to traditional AE sensors.

Banks, Curtis E.↗

NASA NTRS2010

Acoustic Emission Measurement with Fiber Bragg Gratings for Structure Health Monitoring

Banks, Curtis E.↗

NASA NTRS2010

Nondestructive Evaluation (NDE) for Characterizing Oxidation Damage in Cracked Reinforced Carbon-Carbon

In this study, coated reinforced carbon-carbon (RCC) samples of similar structure and composition as that from the NASA space shuttle orbiter's thermal protection system were fabricated with slots in their coating simulating craze cracks. These specimens were used to study oxidation damage detection and characterization using nondestructive evaluation (NDE) methods. These specimens were heat treated in air at 1143 C and 1200 C to create cavities in the carbon substrate underneath the coating as oxygen reacted with the carbon and resulted in its consumption. The cavities varied in diameter from approximately 1 to 3mm. Single-sided NDE methods were used because they might be practical for on-wing inspection, while X-ray micro-computed tomography (CT) was used to measure cavity sizes in order to validate oxidation models under development for carbon-carbon materials. An RCC sample having a naturally cracked coating and subsequent oxidation damage was also studied with X-ray micro-CT. This effort is a follow-on study to one that characterized NDE methods for assessing oxidation damage in an RCC sample with drilled holes in the coating.

Roth, Don J.↗

NASA NTRS2009

NDE for Characterizing Oxidation Damage in Reinforced Carbon-Carbon

In this study, coated reinforced carbon-carbon (RCC) samples of similar structure and composition as that from the NASA space shuttle orbiter s thermal protection system were fabricated with slots in their coating simulating craze cracks. These specimens were used to study oxidation damage detection and characterization using NDE methods. These specimens were heat treated in air at 1143 and 1200 C to create cavities in the carbon substrate underneath the coating as oxygen reacted with the carbon and resulted in its consumption. The cavities varied in diameter from approximately 1 to 3 mm. Single-sided NDE methods were used since they might be practical for on-wing inspection, while x-ray micro-computed tomography (CT) was used to measure cavity sizes in order to validate oxidation models under development for carbon-carbon materials. An RCC sample having a naturally-cracked coating and subsequent oxidation damage was also studied with x-ray micro-CT. This effort is a follow-on study to one that characterized NDE methods for assessing oxidation damage in an RCC sample with drilled holes in the coating. The results of that study are briefly reviewed in this article as well. Additionally, a short discussion on the future role of simulation to aid in these studies is provided.

Roth, Don J.↗

NASA NTRS2009

Nondestructive Evaluation (NDE) for Characterizing Oxidation Damage in Cracked Reinforced Carbon-Carbon (RCC)

In this study, coated reinforced carbon-carbon (RCC) samples of similar structure and composition as that from the NASA space shuttle orbiter's thermal protection system were fabricated with slots in their coating simulating craze cracks. These specimens were used to study oxidation damage detection and characterization using nondestructive evaluation (NDE) methods. These specimens were heat treated in air at 1143 and 1200 C to create cavities in the carbon substrate underneath the coating as oxygen reacted with the carbon and resulted in its consumption. The cavities varied in diameter from approximately 1 to 3 mm. Single-sided NDE methods were used since they might be practical for on-wing inspection, while x-ray micro-computed tomography (CT) was used to measure cavity sizes in order to validate oxidation models under development for carbon-carbon materials. An RCC sample having a naturally-cracked coating and subsequent oxidation damage was also studied with x-ray micro-CT. This effort is a follow-on study to one that characterized NDE methods for assessing oxidation damage in an RCC sample with drilled holes in the coating.

Roth, Don J.↗

NASA NTRS2007

A Software Platform for Post-Processing Waveform-Based NDE

Ultrasonic, microwave, and terahertz nondestructive evaluation imaging systems generally require the acquisition of waveforms at each scan point to form an image. For such systems, signal and image processing methods are commonly needed to extract information from the waves and improve resolution of, and highlight, defects in the image. Since some similarity exists for all waveform-based NDE methods, it would seem a common software platform containing multiple signal and image processing techniques to process the waveforms and images makes sense where multiple techniques, scientists, engineers, and organizations are involved. This presentation describes NASA Glenn Research Center's approach in developing a common software platform for processing waveform-based NDE signals and images. This platform is currently in use at NASA Glenn and at Lockheed Martin Michoud Assembly Facility for processing of pulsed terahertz and ultrasonic data. Highlights of the software operation will be given. A case study will be shown for use with terahertz data. The authors also request scientists and engineers who are interested in sharing customized signal and image processing algorithms to contribute to this effort by letting the authors code up and include these algorithms in future releases.

Roth, Donald J.↗

NASA NTRS2007

NDE Methods for the External Tank Spray on Foam Insulation

The foam thermal protection system (TPS) of the space shuttle External Tank (ET) has provided some unique challenges to the nondestructive testing community. Three nondestructive evaluation methods have been developed to identify defects in the foam TPS of the ET. Terahertz imaging and backscatter radiography have been developed to identify voids in thick foam regions while shearography has been developed to identify shallow delaminations, shallow voids and crush damage in the foam. The basic theory of operation along with factors, determined from a series of designed experiments, affecting the results of these methods will be described. Results from both test panels and flight tank inspections will be provided, along with predicted probability of detection estimates to show the range in defect sizes and types that can be readily detected.

Walker, James L.↗

NASA NTRS2007

Application of Terahertz Radiation to the Detection of Corrosion under the Shuttle's Thermal Protection System

There is currently no method for detecting corrosion under Shuttle tiles except for the expensive process of tile removal and replacement; hence NASA is investigating new NDE methods for detecting hidden corrosion. Time domain terahertz radiation has been applied to corrosion detection under tiles in samples ranging from small lab samples to a Shuttle with positive results. Terahertz imaging methods have been able to detect corrosion at thicknesses of 5 mils or greater under 1" thick Shuttle tiles and 7-12 mils or greater under 2" thick Shuttle tiles.

Madaras, Eric I.↗

NASA NTRS2006

The Evolution of Nondestructive Evaluation Methods for the Space Shuttle External Tank Thermal Protection System

Three nondestructive evaluation methods are being developed to identify defects in the foam thermal protection system (TPS) of the Space Shuttle External Tank (ET). Shearography is being developed to identify shallow delaminations, shallow voids and crush damage in the foam while terahertz imaging and backscatter radiography are being developed to identify voids and cracks in thick foam regions. The basic theory of operation along with factors affecting the results of these methods will be described. Also, the evolution of these methods from lab tools to implementation on the ET will be discussed. Results from both test panels and flight tank inspections will be provided to show the range in defect sizes and types that can be readily detected.

Walker, James L.↗

NASA NTRS2006

Nondestructive Evaluation of Foam Insulation on the Space Shuttle External Tank

Foam loss on the External Tank (ET) during launch can be caused by a number of factors. Voids are the best understood mechanism of foam loss, although it is known that delaminations, cracks and crushed foam can also lead to liberation of foam. Shortly after the Columbia accident, work began on non-destructive evaluation of foam targeted at finding voids and delaminations. After several months of searching for candidate methods capable of inspecting ET foam, the five most promising techniques were taken through a blind test and narrowed down to two methods to develop and use for inspection of the ET. These methods were backscatter radiography and terahertz imaging. The backscatter radiography system measures a test part by detecting Compton backscattered x-ray energy generated by a collimated beam of x-rays directed at the test subject. This collimated beam is scanned across the subject, recording scatter intensity data one pixel at a time until the area of interest is covered. The resulting data can be used to generate an image similar to a radiograph. Some depth information can be gathered utilizing apertures or collimation on the detectors. The detectors are located around the collimated source, making this a single sided inspection. The void detection limit with the currently utilized system is around 0.5 inches in diameter by 0.2 inches high. The terahertz imaging system inspects a test part by utilizing a transceiver to emit a pulse focused at the aluminum skin of the ET, which reflects it back to the transceiver where it is analyzed. The transceiver is scanned across the area of interest until a measurement has been taken at every location. Amplitude, time delay and frequency content are examined to note any discontinuities which may be the result of a void or other type of defect. The pulse currently utilized is in the millimeter wave regime. The void detection limit with this system is around 0.5 inches in diameter by 0.2 inches high. With increased interest in other causes of foam loss following the flight of Discovery in July 2005, laser shearography was added to the techniques used for inspecting ET foam. The shearography method records a sheared image of a laser speckle pattern projected on a test part before And after some sort of excitation. The resultant fringe pattern allows the slope of the out of plane displacement to be measured. For crushed and delaminated foam applications, a non-contact air coupled acoustic force is used to excite the surface of the foam. Regions without defects tend to respond differently to the sound energy than do regions with defects, generating a map of the foam integrity. Foam crushed to a depth of about 0.1 inches is detectable with shearography even after it has relaxed to its original shape.

Richter, Joel↗

NASA NTRS2006

Nondestructive Evaluation of Foam Insulation for the External Tank Return to Flight

Nondestructive evaluation methods have been developed to identify defects in the foam thermal protection system (TPS) of the Space Shuttle External Tank (ET). Terahertz imaging and backscatter radiography have been brought from prototype lab systems to production hardened inspection tools in just a few years. These methods have been demonstrated to be capable of detecting void type defects under many inches of foam which, if not repaired, could lead to detrimental foam loss. The evolution of these methods from lab tools to implementation on the ET will be discussed.

Walker, James L.↗

NASA NTRS2005

Nondestructive Evaluation of Space Shuttle External Tank Foam

During launch of Shuttle Columbia, mission STS-107, a large piece of spray on foam insulation (SOFI) separated from the external tank left bipod ramp area impacting the shuttle orbiter left wing leading edge. "Analysis showed that this large piece of foam struck Columbia on the underside of the left wing after launch. Later, analysis showed that the larger piece struck Columbia on the underside of the left wing, around Reinforced Carbon-Carbon (RCC) panels 5 through 9, at 81.9 seconds after launch. Further photographic analysis revealed that the large foam piece was approximately 21 to 27 inches long and 12 to 18 inches wide and was moving at a relative velocity to the Shuttle stack of 625 to 840 feet per second (416 to 573 miles per hour) at the time of impact." This impact damaged the wing leading edge resulting in loss of orbiter thermal protection. The piece of errant foam was part of a bipod ramp which was designed to meet thermal and aerodynamic requirements in that region of the external tank (ET).

Thom, Robert L.↗

NASA NTRS2005

Acoustic Emission Weld Monitoring in the 2195 Aluminum-Lithium Alloy

Due to its low density, the 2195 aluminum-lithium alloy was developed as a replacement for alloy 2219 in the Space Shuttle External Tank (ET). The external tank is the single largest component of the space shuttle system. It is 154 feet long and 27.6 feet in diameter, and serves as the structural backbone for the shuttle during launch, absorbing most of the 7 million plus pounds of thrust produced. The almost 4% decrease in density between the two materials provides an extra 7500 pounds of payload capacity necessary to put the International Space Station components into orbit. The ET is an all-welded structure; hence, the requirement is for up to five rewelds without hot cracking. Unfortunately, hot cracking during re-welding or repair operations was occurring and had to be dealt with before the new super lightweight tank could be used. Weld metal porosity formation was also of concern because it leads to hot cracking during weld repairs. Accordingly, acoustic emission (AE) nondestructive testing was employed to monitor the formation of porosity and hot cracks in order to select the best filler metal and optimize the weld schedule. The purpose of this work is to determine the feasibility of detecting hot cracking in welded aluminum-lithium (Al-Li) structures through the analysis of acoustic emission data. By acoustically characterizing the effects of reheating during a repair operation, the potential for hidden flaws coalescing and becoming "unstable" as the panel is repaired could be reduced. Identification of regions where microcrack growth is likely to occur and the location of active flaw growth in the repair weld will provide the welder with direct feedback as to the current weld quality enabling adjustments to the repair process be made in the field. An acoustic emission analysis of the source mechanisms present during welding has been conducted with the goals of locating regions in the weld line that are susceptible to damage from a repair operation, identifying the formation of critically sized flaws and providing accept/reject criteria for the quality of a weld as it is performed.

Walker, James L.↗

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.↗