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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS1985

Nondestructive evaluation of composites by optical time domain reflectometry in imbedded optical fibers

The use of imbedded optical fibers to obtain dynamic two-dimensional dynamic-strain measurements by optical time-domain reflectometry (OTDR) in laminated composites is described. The fundamental principles of OTDR are reviewed, and the basic parameters resolution and dynamic range are defined. Results of OTDR measurements on 30-cm square plates of 0/90/90/0-deg graphite epoxy composite with type 1506 optical fibers imbedded in a serpentine pattern between (and parallel to the reinforcing fibers of) the 90-deg plates are presented in graphs and briefly characterized. It is estimated that processing the OTDR data with simple techniques could permit strain detection of the order 0.00001 at sampling rates as high as 1/ms.

Claus, R. O.↗
DOE OSTI2025

High-Intensity UV Exposure for the Rapid Screening of Silicon Photovoltaic Architectures

Advanced Si photovoltaic architectures incorporate different materials and processing pathways that influence degradation modes. Ultraviolet-induced degradation (UVID) is an understudied degradation mode for advanced cell architectures and is of increasing concern to industry due to growing adoption of UV-transparent encapsulation and bifacial technologies. In order to adopt new and evolving technologies confidently, novel component materials and processing techniques must be evaluated and designed for long-term stability, in addition to the conventional design focus on efficiency. In this work, a study protocol framework is presented for the rapid screening of unencapsulated devices against UVID. Unencapsulated passivated emitter rear contact (PERC) and tunnel oxide passivated contact (TOPCon) devices were aged under different UV irradiance intensities and measured via conventional nondestructive electrical characterization methods to assess performance degradation. Based on the results, protocol efficacy and recommendations for further study are discussed. As a result, this work is part of a broader effort to develop rapid screening processes that cut across architectures and exposure conditions to aid module manufacturers in vetting new materials choices for long-term stability.

Accelerated exposure↗
NASA NTRS1990

Input-output characterization of fiber reinforced composites by P waves

Input-output characterization of fiber composites is studied theoretically by tracing P waves in the media. A new path motion to aid in the tracing of P and the reflection generated SV wave paths in the continuum plate is developed. A theoretical output voltage from the receiving transducer is calculated for a tone burst. The study enhances the quantitative and qualitative understanding of the nondestructive evaluation of fiber composites which can be modeled as transversely isotropic media.

Renneisen, John D.↗
NASA NTRS2002

Detection of Intergranular Corrosion in Cold Plate Face Sheets

Cold plates are critical for cooling electronic systems in the shuttle. As a result of the environmental conditions in which they operate, water can condense between them and a support shelf. In some cases, this water results in intergranular corrosion in the face sheet. If the intergranular corrosion sufficiently penetrates the face sheet, a coolant leak could occur and jeopardize cold plate operation. This paper examines techniques for detecting and characterizing the intergranular corrosion, to enable recertification of cold plates that have been in operation for 15 plus years. Intergranular corrosion was artificially induced in the face sheets of a series of cold plate specimens using an electrochemical process. Some of the cold plate specimens were separated for destructive characterization of the extent of corrosion produced by the electrochemical process and to insure the induced corrosion was intergranular. The rest of the specimens were characterized nondestructively using several techniques. X-ray tomography and ultrasonic techniques provided the best indication of corrosion in these specimens and will be the focus of this paper. An x-ray tomography technique was shown to be the most effective technique for characterizing depth of the intergranular corrosion. From these measurements, corrosion profile maps were developed that were consistent with subsequent destructive evaluations of the specimens. This enabled the assessment of NDE (ondestructive evaluation) standards to evaluate the viability of other NDE techniques. Due to system constraints, a different technique must be used to inspect an entire cold plate. An ultrasonic technique was shown to be very reliable for detection of corrosion in the unbacked regions of the face sheet. The ultrasonic technique was performed in an alcohol bath to avoid additional corrosion during the NDE evaluation. A pulse echo technique that focuses on the RMS value of the signal is shown to be very sensitive to the presence of intergranular corrosion.

Winfree, William P.↗
NASA NTRS1994

Composite Material Property Nondestructive Characterization Using Obliquely Insonified Ultrasonic Waves

The analysis of reflected ultrasonic waves induced by oblique insonification of composite materials is a powerful tool for providing informations about defects and material properties. A device was developed to manipulate a pair of transmitting and receiving transducers at vrious angles of wave incidence and propagation with the fiber orientation.

Non-Destructive Evaluation Composites Mechanical P↗
DOE OSTI2025

Bimodal Visualization of Industrial X-Ray and Neutron Computed Tomography Data

Advanced manufacturing creates increasingly complex objects with material compositions that are often difficult to characterize by a single modality. Our collaborating domain scientists are going beyond traditional methods by employing both X-ray and neutron computed tomography to obtain complementary representations expected to better resolve material boundaries. However, the use of two modalities creates its own challenges for visualization, requiring either complex adjustments of bimodal transfer functions or the need for multiple views. Together with experts in nondestructive evaluation, we designed a novel interactive bimodal visualization approach to create a combined view of the co-registered X-ray and neutron acquisitions of industrial objects. Using an automatic topological segmentation of the bivariate histogram of X-ray and neutron values as a starting point, the system provides a simple yet effective interface to easily create, explore, and adjust a bimodal visualization. Here, we propose a widget with simple brushing interactions that enables the user to quickly correct the segmented histogram results. Our semiautomated system enables domain experts to intuitively explore large bimodal datasets without the need for either advanced segmentation algorithms or knowledge of visualization techniques. We demonstrate our approach using synthetic examples, industrial phantom objects created to stress bimodal scanning techniques, and real-world objects, and we discuss expert feedback.

image segmentation↗
NASA NTRSDate not supplied

Characterization of NU-LHT-4M Lunar Regolith Simulant Using Different Raman Configurations

As much as possible, structures to help sustain a long-term human presence on the moon will be constructed via in-situ resource utilization (ISRU) from lunar regolith. Various processes have been proposed to make lunar regolith-based construction materials, but one complication is that the lunar regolith is relatively complex in terms of composition and can vary quite significantly from one site to another. Some of these methods to make lunar regolith-based construction materials are quite sensitive to the composition and so in-situ methods for evaluating the composition of the lunar regolith could be critical. Various analytical instrumentation has been proposed for in-situ characterization of the composition of regolith on planetary bodies. Raman spectroscopy has been suggested and has some advantages over other in-situ techniques, such as potential for relatively high spatial resolution, direct determination of the mineralogy (while other methods may only infer the mineralogy), nondestructive analysis, relatively simple instrument configurations, and minimal sample preparation/handling. For example, Raman instrumentation has already been deployed in rover-based missions to Mars. Previously, we developed the Standoff Ultracompact Micro-Raman Sensor (SUCR), which is a portable Raman spectroscopy instrument capable to be integrated into a rover or onto a lander. Here, we present work on Raman spectroscopy measurements of NU-LHT-4M lunar simulant using three different Raman instruments with different configurations for collecting Raman data with the goal to explore the effect of these different configurations on the results, especially for use in a lunar environment.

Raman Spectroscopy↗
NASA NTRS1994

Nondestructive evaluation of fatigue damage in aluminum 2024 by x-ray diffraction

Aluminum alloys are widely used in the automobile and aerospace industries. This is due to their attractive low density-high modulus and low density-high strength characteristics. Unfortunately, cyclic stress-strain deformations alter the microstructure of aluminum alloys when they are placed into service. These structural changes can lead to fatigue damage and ultimately service failure. Since x-ray diffraction analysis is known to be a sensitive nondestructive indicator of structural changes due to deformations, this technique is being used to evaluate changes in the microstructure of cycled aluminum 2024 commercial alloys. Line shapes, widths, and positions in an x-ray diffraction pattern depend on microstructural properties such as grain size, grain orientation, residual stress, microstrain, etc. Changes in the microstructure due to fatigue will appear as changes in the diffraction pattern. One parameter used to characterize a reflection in a diffraction pattern is the full width at half maximum (FWHM). Preliminary x-ray diffraction results on cycled Al 2024 indicate that the (111) and (222) reflections of the matrix phase do not show any variations in the FWHM due to an increase in the fatigue cycles. However, the FWHM of the (200) and (400) reflections of the same phase unexpectedly showed a dramatic decrease. These results can be interpreted as due to the relaxation of some initial nonuniform residual stresses in the matrix phase lattice. Further work is in progress to evaluate the FWHM of the second phase of the cycled alloys.

Ferguson, Milton W.↗
NASA NTRS2006

High-Performance Scanning Acousto-Ultrasonic System

A high-performance scanning acousto-ultrasonic system, now undergoing development, is designed to afford enhanced capabilities for imaging microstructural features, including flaws, inside plate specimens of materials. The system is expected to be especially helpful in analyzing defects that contribute to failures in polymer- and ceramic-matrix composite materials, which are difficult to characterize by conventional scanning ultrasonic techniques and other conventional nondestructive testing techniques. Selected aspects of the acousto-ultrasonic method have been described in several NASA Tech Briefs articles in recent years. Summarizing briefly: The acousto-ultrasonic method involves the use of an apparatus like the one depicted in the figure (or an apparatus of similar functionality). Pulses are excited at one location on a surface of a plate specimen by use of a broadband transmitting ultrasonic transducer. The stress waves associated with these pulses propagate along the specimen to a receiving transducer at a different location on the same surface. Along the way, the stress waves interact with the microstructure and flaws present between the transducers. The received signal is analyzed to evaluate the microstructure and flaws. The specific variant of the acousto-ultrasonic method implemented in the present developmental system goes beyond the basic principle described above to include the following major additional features: Computer-controlled motorized translation stages are used to automatically position the transducers at specified locations. Scanning is performed in the sense that the measurement, data-acquisition, and data-analysis processes are repeated at different specified transducer locations in an array that spans the specimen surface (or a specified portion of the surface). A pneumatic actuator with a load cell is used to apply a controlled contact force. In analyzing the measurement data for each pair of transducer locations in the scan, the total (multimode) acousto-ultrasonic response of the specimen is utilized. The analysis is performed by custom software that extracts parameters of signals in the time and frequency domains. The computer hardware and software provide both real-time and postscan processing and display options. For example, oscilloscope displays of waveforms and power spectral densities are available in real time. Images can be computed while scanning continues. Signals can be digitally preprocessed and/or post-processed by filtering, windowing, time-segmenting, and running-waveform-averaging algorithms. In addition, the software affords options for off-line simulation of the waveform-data-acquisition and scanning processes. In tests, the system has been shown to be capable of characterizing microstructural changes and defects in SiC/SiC and C/SiC ceramic-matrix composites. Delaminations, variations in density, microstructural changes attributable to infiltration by silicon, and crack-space indications (defined in the next sentence) have been revealed in images formed from several time- and frequency-domain parameters of scanning acousto-ultrasonic signals. The crack-space indications were image features that were not revealed by other nondestructive testing methods and are so named because they turned out to mark locations where cracking eventually occurred.

Roth, Don↗
NASA NTRS1998

Single-Transducer, Ultrasonic Imaging Method for High-Temperature Structural Materials Eliminates the Effect of Thickness Variation in the Image

NASA Lewis Research Center's Life Prediction Branch, in partnership with Sonix, Inc., and Cleveland State University, recently advanced the development of, refined, and commercialized an advanced nondestructive evaluation (NDE) inspection method entitled the Single Transducer Thickness-Independent Ultrasonic Imaging Method. Selected by R&D Magazine as one of the 100 most technologically significant new products of 1996, the method uses a single transducer to eliminate the superimposing effects of thickness variation in the ultrasonic images of materials. As a result, any variation seen in the image is due solely to microstructural variation. This nondestructive method precisely and accurately characterizes material gradients (pore fraction, density, or chemical) that affect the uniformity of a material's physical performance (mechanical, thermal, or electrical). Advantages of the method over conventional ultrasonic imaging include (1) elimination of machining costs (for precision thickness control) during the quality control stages of material processing and development and (2) elimination of labor costs and subjectivity involved in further image processing and image interpretation. At NASA Lewis, the method has been used primarily for accurate inspections of high temperature structural materials including monolithic ceramics, metal matrix composites, and polymer matrix composites. Data were published this year for platelike samples, and current research is focusing on applying the method to tubular components. The initial publicity regarding the development of the method generated 150 requests for further information from a wide variety of institutions and individuals including the Federal Bureau of Investigation (FBI), Lockheed Martin Corporation, Rockwell International, Hewlett Packard Company, and Procter & Gamble Company. In addition, NASA has been solicited by the 3M Company and Allison Abrasives to use this method to inspect composite materials that are manufactured by these companies.

Roth, Don J.↗
NASA NTRS1997

Study of Acoustic Emissions from Composites

The nondestructive evaluation (NDE) of future propulsion systems utilizing advanced composite structures for the storage of cryogenic fuels, such as liquid hydrogen or oxygen, presents many challenges. Economic justification for these structures requires light weight, reusable components with an infrastructure allowing periodic evaluation of structural integrity after enduring demanding stresses during operation. A major focus has been placed on the use of acoustic emission NDE to detect propagating defects, in service, necessitating an extensive study into characterizing the nature of acoustic signal propagation at very low temperatures and developing the methodology of applying AE sensors to monitor cryogenic components. This work addresses the question of sensor performance in the cryogenic environment. Problems involving sensor mounting, spectral response and durability are addressed. The results of this work provides a common point of measure from which sensor selection can be made when testing composite components at cryogenic temperatures.

Walker, James L.↗
NASA NTRS1997

Study Acoustic Emissions from Composites

The nondestructive evaluation (NDE) of future propulsion systems utilizing advanced composite structures for the storage of cryogenic fuels, such as liquid hydrogen or oxygen, presents many challenges. Economic justification for these structures requires, light weight, reusable components with an infrastructure allowing periodic evaluation of structural integrity after enduring demanding stresses during operation. A major focus has been placed on the use of acoustic emission NDE to detect propagating defects, in service, necessitating an extensive study into characterizing the nature of acoustic signal propagation at very low temperatures and developing the methodology of applying AE sensors to monitor cryogenic components. This work addresses the question of sensor performance in the cryogenic environment. Problems involving sensor mounting, spectral response and durability are addressed. The results of this work provides a common point of measure from which sensor selection can be made when testing composite components at cryogenic temperatures.

Walker, James L.↗
NASA NTRS2010

Development and Implementation of Nationally Recognized Laboratory for Material Characterization in the Microwave and Millimeter Wave Bands

This report provides a progress update for establishing a laboratory for material characterization in the microwave and millimeter wave bands. During the launch of STS-124 a large area of refractory bricks was liberated from the flame trench built for the exhaust of the solid rocket motors (SRM). The inspection of the liberated area revealed many defects, debonds, corrosion and voids that are a cause for concern relating to the health of the entire flame trench wall. A request for assistance was received for the nondestructive evaluation (NDE) of these anomalies behind the refractory bricks, with the primary interest being a health assessment based on the quality of the brick, epoxy and concrete bond.

Hepburn, Frank L.↗
NASA NTRS2004

Characterization of C/Enhanced SiC Composite During Creep-Rupture Tests Using an Ultrasonic Guided Wave Scan System

An ultrasonic guided wave scan system was used to nondestructively monitor damage over time and position in a C/enhanced SiC sample that was creep tested to failure at 1200 C in air at a stress of 69 MPa (10 ksi). The use of the guided wave scan system for mapping evolving oxidation profiles (via porosity gradients resulting from oxidation) along the sample length and predicting failure location was explored. The creep-rupture tests were interrupted for ultrasonic evaluation every two hours until failure at approx. 17.5 cumulative hours.

Roth, Don J.↗
NASA NTRS2012

Development of Standards for Nondestructive Evaluation of COPVs Used in Aerospace Applications

Composite OverWrapped Pressure Vessels (COPVs) are currently accepted by NASA based on design and qualification requirements and generally not verified by NDE for the following reasons: (1) Manufactures and end users generally do not have experience and validated quantitative methods of detecting flaws and defects of concern (1-a) If detected, the flaws are not adequately quantified and it is unclear how they may contribute to degradation in mechanical response (1-b) Carbon-epoxy COPVs also extremely sensitive to impact damage and impacts may be below the visible detection threshold (2) If damage is detected, this generally results in rejection since the effect on mechanical response is generally not known (3) NDE response has not generally been fully characterized, probability of detection (POD) established, and processes validated for evaluation of vessel condition as manufactured and delivered.

Waller, Jess M.↗
NASA NTRS1989

A study of the stress wave factor technique for evaluation of composite materials

The acousto-ultrasonic approach for nondestructive evaluation provides a measurement procedure for quantifying the integrated effect of globally distributed damage characteristic of fiber reinforced composite materials. The evaluation procedure provides a stress wave factor that correlates closely with several material performance parameters. The procedure was investigated for a variety of materials including advanced composites, hybrid structure bonds, adhesive bonds, wood products, and wire rope. The research program focused primarily on development of fundamental understanding and applications advancements of acousto-ultrasonics for materials characterization. This involves characterization of materials for which detection, location, and identification of imperfections cannot at present be analyzed satisfactorily with mechanical performance prediction models. In addition to presenting definitive studies on application potentials, the understanding of the acousto-ultrasonic method as applied to advanced composites is reviewed.

Duke, J. C., Jr.↗
DOE OSTI2024

Enhancing NDE Reliability for Grade 91 Steel Welds: Ultrasonic Imaging and Microstructural Correlations

Ensuring the integrity of Grade 91 (9Cr-1Mo-V) steel welds is vital for the safe and reliable operation of fossil fuel–fired and nuclear power plants. Here, this study applies an imaging technique for the ultrasonic characterization of two Grade 91 steel welds created with cold metal transfer and flux-cored arc welding processes. Ultrasonic immersion testing in the through-transmission configuration was employed to generate shear waves, which helped identify the weld metal, heat-affected zone, and base metal regions. These weld microstructures were also correlated to their ultrasonic images using metallography, ultrasonic amplitude, hardness measurements, and grain size. The findings from this study can assist practitioners in developing new nondestructive evaluation technologies, improving the inspection reliability of creep strength–enhanced ferritic steel welds by potentially identifying weld microstructure regions susceptible to creep-type failures.

Grade 91 steel↗
NASA NTRS1983

NDE detectability of fatigue type cracks in high strength alloys

Specimens suitable for investigating the reliability of production nondestructive evaluation (NDE) to detect tightly closed fatigue cracks in high strength alloys representative of those materials used in spacecraft engine/booster construction were produced. Inconel 718 was selected as representative of nickel base alloys and Haynes 188 was selected as representative of cobalt base alloys used in this application. Cleaning procedures were developed to insure the reusability of the test specimens and a flaw detection reliability assessment of the fluorescent penetrant inspection method was performed using the test specimens produced to characterize their use for future reliability assessments and to provide additional NDE flaw detection reliability data for high strength alloys. The statistical analysis of the fluorescent penetrant inspection data was performed to determine the detection reliabilities for each inspection at a 90% probability/95% confidence level.

Christner, B. K.↗