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NASA NTRS2013

Common Practice Lightning Strike Protection Characterization Technique to Quantify Damage Mechanisms on Composite Substrates

To support FAA certification airworthiness standards, composite substrates are subjected to lightning direct-effect electrical waveforms to determine performance characteristics of the lightning strike protection (LSP) conductive layers used to protect composite substrates. Test results collected from independent LSP studies are often incomparable due to variability in test procedures & applied practices at different organizations, which impairs performance correlations between different LSP data sets. Under a NASA supported contract, The Boeing Company developed technical procedures and documentation as guidance in order to facilitate a test method for conducting universal common practice lightning strike protection test procedures. The procedures obtain conformity in future lightning strike protection evaluations to allow meaningful performance correlations across data sets. This universal common practice guidance provides the manufacturing specifications to fabricate carbon fiber reinforced plastic (CFRP) test panels, including finish, grounding configuration, and acceptable methods for pretest nondestructive inspection (NDI) and posttest destructive inspection. The test operations guidance elaborates on the provisions contained in SAE ARP5416 to address inconsistencies in the generation of damage protection performance data, so as to provide for maximum achievable correlation across capable lab facilities. In addition, the guidance details a direct effects test bed design to aid in quantification of the multi-physical phenomena surrounding a lightning direct attachment supporting validation data requirements for the development of predictive computational modeling. The lightning test bed is designed to accommodate a repeatable installation procedure to secure the test panel and eliminate test installation uncertainty. It also facilitates a means to capture the electrical waveform parameters in 2 dimensions, along with the mechanical displacement and thermal heating parameters which occur during lightning attachment. Following guidance defined in the universal common practice LSP test documents, protected and unprotected CFRP panels were evaluated at 20, 40 and 100KAmps. This report presents analyzed data demonstrating the scientific usefulness of the common practice approach. Descriptions of the common practice CFRP test articles, LSP test bed fixture, and monitoring techniques to capture the electrical, mechanical and thermal parameters during lightning attachment are presented here. Two methods of measuring the electrical currents were evaluated, inductive current probes and a newly developed fiberoptic sensor. Two mechanical displacement methods were also examined, optical laser measurement sensors and a digital imaging correlation camera system. Recommendations are provided to help users implement the common practice test approach and obtain LSP test characterizations comparable across data sets.

Szatkowski, George N.↗

NASA NTRSDate not supplied

Material Property Estimation in Thin Battery Components Using Guided Wave Measurement, Experimental Dispersion Curve Extraction and Finite Element Modeling

At NASA, we are investigating nondestructive evaluation (NDE) and structural health monitoring (SHM) techniques to detect precursors of thermal runaway failure in lithium metal based lithium ion batteries (LIB). The approach is centered on computational simulation models to guide inspection and aid in interpretation of results. Since lithium metal LIBs have combinations of solid and fluid-filled porous materials, obtaining accurate material properties is both challenging and critical for successful simulation of battery inspection. To this end, we investigated a multi-verification approach for material characterization of thin battery components. First, a laser Doppler vibrometer (LDV) was used to measure guided wave fields in thin (microns-thick) battery components subject to broadband excitation. The time-space wavefield data was converted to frequency-wave number data to extract guided wave dispersion curves. A data visualization and post processing graphics user interface (GUI) was developed at NASA to aid the data exploration and analysis. Due to the thinness of the samples, low frequency-thickness-product plate wave approximations allowed for the calculation of closed-form solutions for material elastic property estimation. These approximations were then verified by calculating the Lamb wave solutions using the previously obtained material properties. Finally, the estimated elastic material properties were implemented in a COMSOL simulation model, and dispersion curves were extracted from simulation results. The dispersion curves and derived material properties were then compared to the analysis results from the experimental data. These comparisons informed on the accuracy of the measured material properties and helped demonstrate the accuracy of the finite element analysis (FEA) computational models. This assessment will prove vital when we start simulating more complex multi-layer components and poroelastic media. This paper gives a brief background of the problem space, outlines the workflow for data analysis and verification, shows results from the workflow, and gives an overview of future plans for simulation of lithium metal LIB inspection.

Peter Juarez↗

DOE OSTI2022

Applying Acoustic Emission to Large Format Additive Manufacturing

Large format additive manufacturing (AM) is being adapted as a method of producing large structures in a short lead time and cost-effective way. With the growing advancement in AM techniques and application, machine monitoring and part qualification is highly needed. There has been leading research focused on the manufacturing development and feedstock material but minimum research on the structural health monitoring (SHM), defect detection, and nondestructive evaluation (NDE) for large format AM. Scanning large structure using conventional nondestructive testing (NDT) techniques, such as ultrasound or X-ray, and searching for potential defects can be very time consuming, challenging and cost prohibitive. Acoustic emission (AE) is a passive technique that can be used to monitor and locate defect progression in large structures by distributing group of sensors around the part. This research outlines the necessary procedure for implementing AE to AM as a reliability method. The topics this research will display are: (a) Wave propagation/velocity evaluation, (b) an AE attenuation characterization for the anisotropic printed structure and material, (c) background noise measurements of the extruder and gantry system, and (d) assist in optimal sensor selection and placement for monitoring large AM structures with demonstration. This work establishes the foundation for scaling up the SHM-AE system for the large additive platform.

Spencer, Ryan↗

NASA NTRS1986

Nondestructive evaluation of structural ceramics

Research on nondestructive evaluation (NDE) of structural ceramics for heat engine applications is reviewed. Microfocus radiography and scanning laser acoustic microscopy are the NDE techniques highlighted. The techniques were applied to research samples of sintered silicon nitride and silicon carbide in the form of modulus-of-rupture (MOR) bars. The strength and limitations of the aforementioned techniques are given in terms of probablility of detection for voids in green and sintered MOR bars. Voids for this purpose were introduced by seeding green ceramic bars and characterizing each void in terms of its size, shape, location, and nature before and after sintering. The effects of material density, microstructure, surface finish, thickness, void depth, and size characteristics on detectability are summarized.

Vary, Alex↗

NASA NTRS1991

Quantitative nondestructive evaluation: Requirements for tomorrow's reliability

Quantitative Nondestructive Evaluation (QNDE) is the technology of measurement, analysis, and prediction of the state of material/structural systems for safety, reliability, and mission assurance. QNDE has impact on everyday life from the cars we drive, the planes we fly, the buildings we work or live in, literally to the infrastructure of our world. Here, researchers highlight some of the new sciences and technologies that are part of a safer, cost effective tomorrow. Specific technologies that are discussed are thermal QNDE of aircraft structural integrity, ultrasonic QNDE for materials characterization, and technology spinoffs from aerospace to the medical sector. In each case, examples are given of how new requirements result in enabling measurement technologies, which in turn change the boundaries of design/practice.

Heyman, Joseph S.↗

DOE OSTI2023

Nondestructive property and defect characterization using X-rays and neutrons

As advanced manufacturing (AM) continues to mature as a fabrication technique, interest in its use for the fabrication of nuclear components continues to grow. AM nuclear parts offer the ability to create parts with complex and non-standard geometries that cannot be produced using traditional manufacturing techniques, circumvention of supply chain issues, and reduction of time from design to implementation. However, components fabricated with AM techniques must undergo nondestructive examination (NDE) to ensure they are fabricated to the required specifications to ensure safe and proper operation. The Advanced Materials and Manufacturing Technologies (AMMT) program has undertaken initial exploratory studies on several NDE techniques to evaluate their feasibility for research and development (R&D), as well as Quality Assurance and Quality Control (QA/QC), and in-service inspections of AM parts. This work describes research results on several techniques, including X-ray and neutron tomography and scattering, as well as photothermal radiometry. The experimental results are described and an overview for each techniques’ potential use on AM parts in the various phases of part development and lifetime is given. Finally, future directions for technique development and application to AM nuclear components are described.

36 MATERIALS SCIENCE↗

NASA NTRS2002

Development of a High Performance Acousto-ultrasonic Scan System

Roth, D. J.↗

NASA NTRS2003

High-Performance Acousto-Ultrasonic Scan System Being Developed

Acousto-ultrasonic (AU) interrogation is a single-sided nondestructive evaluation (NDE) technique employing separated sending and receiving transducers. It is used for assessing the microstructural condition and distributed damage state of the material between the transducers. AU is complementary to more traditional NDE methods, such as ultrasonic cscan, x-ray radiography, and thermographic inspection, which tend to be used primarily for discrete flaw detection. Throughout its history, AU has been used to inspect polymer matrix composites, metal matrix composites, ceramic matrix composites, and even monolithic metallic materials. The development of a high-performance automated AU scan system for characterizing within-sample microstructural and property homogeneity is currently in a prototype stage at NASA. This year, essential AU technology was reviewed. In addition, the basic hardware and software configuration for the scanner was developed, and preliminary results with the system were described. Mechanical and environmental loads applied to composite materials can cause distributed damage (as well as discrete defects) that plays a significant role in the degradation of physical properties. Such damage includes fiber/matrix debonding (interface failure), matrix microcracking, and fiber fracture and buckling. Investigations at the NASA Glenn Research Center have shown that traditional NDE scan inspection methods such as ultrasonic c-scan, x-ray imaging, and thermographic imaging tend to be more suited to discrete defect detection rather than the characterization of accumulated distributed micro-damage in composites. Since AU is focused on assessing the distributed micro-damage state of the material in between the sending and receiving transducers, it has proven to be quite suitable for assessing the relative composite material state. One major success story at Glenn with AU measurements has been the correlation between the ultrasonic decay rate obtained during AU inspection and the mechanical modulus (stiffness) seen during fatigue experiments with silicon carbide/silicon carbide (SiC/SiC) ceramic matrix composite samples. As shown in the figure, ultrasonic decay increased as the modulus decreased for the ceramic matrix composite tensile fatigue samples. The likely microstructural reason for the decrease in modulus (and increase in ultrasonic decay) is the matrix microcracking that commonly occurs during fatigue testing of these materials. Ultrasonic decay has shown the capability to track the pattern of transverse cracking and fiber breakage in these composites.

Roth, Don J.↗

NASA NTRS2003

High-Performance Acousto-Ultrasonic Scan System Being Developed

Acousto-ultrasonic (AU) interrogation is a single-sided nondestructive evaluation (NDE) technique employing separated sending and receiving transducers. It is used for assessing the microstructural condition and distributed damage state of the material between the transducers. AU is complementary to more traditional NDE methods, such as ultrasonic cscan, x-ray radiography, and thermographic inspection, which tend to be used primarily for discrete flaw detection. Throughout its history, AU has been used to inspect polymer matrix composites, metal matrix composites, ceramic matrix composites, and even monolithic metallic materials. The development of a high-performance automated AU scan system for characterizing within-sample microstructural and property homogeneity is currently in a prototype stage at NASA. This year, essential AU technology was reviewed. In addition, the basic hardware and software configuration for the scanner was developed, and preliminary results with the system were described. Mechanical and environmental loads applied to composite materials can cause distributed damage (as well as discrete defects) that plays a significant role in the degradation of physical properties. Such damage includes fiber/matrix debonding (interface failure), matrix microcracking, and fiber fracture and buckling. Investigations at the NASA Glenn Research Center have shown that traditional NDE scan inspection methods such as ultrasonic c-scan, x-ray imaging, and thermographic imaging tend to be more suited to discrete defect detection rather than the characterization of accumulated distributed microdamage in composites. Since AU is focused on assessing the distributed microdamage state of the material in between the sending and receiving transducers, it has proven to be quite suitable for assessing the relative composite material state. One major success story at Glenn with AU measurements has been the correlation between the ultrasonic decay rate obtained during AU inspection and the mechanical modulus (stiffness) seen during fatigue experiments with silicon carbide/silicon carbide (SiC/SiC) ceramic matrix composite samples. As shown in the figure, ultrasonic decay increased as the modulus decreased for the ceramic matrix composite tensile fatigue samples. The likely microstructural reason for the decrease in modulus (and increase in ultrasonic decay) is the matrix microcracking that commonly occurs during fatigue testing of these materials. Ultrasonic decay has shown the capability to track the pattern of transverse cracking and fiber breakage in these composites.

Roth, Don J.↗

NASA NTRS2014

Infrared Contrast Analysis Technique for Flash Thermography Nondestructive Evaluation

The paper deals with the infrared flash thermography inspection to detect and analyze delamination-like anomalies in nonmetallic materials. It provides information on an IR Contrast technique that involves extracting normalized contrast verses time evolutions from the flash thermography infrared video data. The paper provides the analytical model used in the simulation of infrared image contrast. The contrast evolution simulation is achieved through calibration on measured contrast evolutions from many flat bottom holes in the subject material. The paper also provides formulas to calculate values of the thermal measurement features from the measured contrast evolution curve. Many thermal measurement features of the contrast evolution that relate to the anomaly characteristics are calculated. The measurement features and the contrast simulation are used to evaluate flash thermography inspection data in order to characterize the delamination-like anomalies. In addition, the contrast evolution prediction is matched to the measured anomaly contrast evolution to provide an assessment of the anomaly depth and width in terms of depth and diameter of the corresponding equivalent flat-bottom hole (EFBH) or equivalent uniform gap (EUG). The paper provides anomaly edge detection technique called the half-max technique which is also used to estimate width of an indication. The EFBH/EUG and half-max width estimations are used to assess anomaly size. The paper also provides some information on the "IR Contrast" software application, half-max technique and IR Contrast feature imaging application, which are based on models provided in this paper.

Koshti, Ajay↗

DOE OSTI2022

Material Characterization of Grade 91 Steel Welds using, Micro-resolution Ultrasonic Imaging System

Grade 91 (9Cr-1Mo-V) steel is a common structural material for fossil-fuel fired and nuclear power plants because of its creep strength and oxidation resistance at high temperatures. In this research, we studied the feasibility of correlating the high-resolution images obtained from the immersion ultrasonic imaging technique to microstructure regions in Grade 91 steel plate weldments. The high-resolution ultrasonic images presented in this paper were generated using a 20-MHz focused transducer as the transmitter, and a laser vibrometer as the receiver in the through transmission configuration to produce longitudinal and shear waves. This nondestructive evaluation (NDE) method was used to identify the Fusion Zone (FZ), Heat-Affected Zone (HAZ), and Base Metal (BM) regions of Grade 91 cold metal transfer (CMT) and flux core arc welds (FCAW). The ultrasonic imaging results were analyzed using beam propagation amplitudes and homogeneity, which in turn were used to relate the different microstructure regions of the FCAW and CMT welded samples. With this study, we were able to identify highly susceptible microstructures in the weld that could potentially promote creep type failures.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS1984

Subcritical Fracture Propagation in Rocks: an Examination Using the Methods of Fracture Mechanics and Non-Destructive Testing

An experimental investigation of tensile rock fracture is presented with an emphasis on characterizing time dependent crack growth using the methods of fracture mechanics. Subcritical fracture experiments were performed in moist air on glass and five different rock types at crack velocities using the double torsion technique. The experimental results suggest that subcritical fracture resistance in polycrystals is dominated by microstructural effects. Evidence for gross violations of the assumptions of linear elastic fracture mechanics and double torsion theory was found in the tests on rocks. In an effort to obtain a better understanding of the physical breakdown processes associated with rock fracture, a series of nondestructive evaluation tests were performed during subcritical fracture experiments on glass and granite. Comparison of the observed process zone shape with that expected on the basis of a critical normal principal tensile stress criterion shows that the zone is much more elongated in the crack propagation direction than predicted by the continuum based microcracking model alone.

Swanson, P. L.↗

NASA NTRS1980

Ceramic applications in turbine engines

Ceramic material characterization and testing of ceramic nozzle vanes, turbine tip shrouds, and regenerators disks at 36 C above the baseline engine TIT and the design, analysis, fabrication and development activities are described. The design of ceramic components for the next generation engine to be operated at 2070 F was completed. Coupons simulating the critical 2070 F rotor blade was hot spin tested for failure with sufficient margin to quality sintered silicon nitride and sintered silicon carbide, validating both the attachment design and finite element strength. Progress made in increasing strength, minimizing variability, and developing nondestructive evaluation techniques is reported.

Hudson, M. S.↗

NASA NTRS2003

Delaminations Investigated With Ultrasonic Spectroscopy

A previous study suggested that the ultrasonic spectroscopy technique identified possible disbonds or delaminations in polymer matrix composite (PMC) rings sectioned from flywheel rotors (ref. 1). These results went unsubstantiated by other nondestructive evaluation (NDE) methods. To explain the results, PMC rings were further investigated with ultrasonic spectroscopy (ref. 2). The ultrasonic spectroscopy system utilizes a continuous-swept sine waveform as the input. After the swept sine wave traverses the material, the captured waveform is subjected to two fast Fourier transforms. The second fast Fourier transform along with equalization of the frequency spectrum, allows for evaluation of the fundamental resonant frequency. The full-thickness resonance, the resonance corresponding to the location of the intentional disbond, and the frequency spectrum were examined in an effort to characterize the sensitivity of the NDE method to various delamination conditions.

Cosgriff, Laura M.↗

NASA NTRSDate not supplied

An Overview of Research in Nondestructive Evaluation at the National Aeronautics and Space Administration’s Langley Research Center

The primary focus of the nondestructive evaluation (NDE) effort at Langley Research Center (LaRC) is to pioneer advances in NDE and structural health monitoring (SHM) through fundamental scientific research, technology development, and transferring these to the scientific and aerospace communities. This research supports a variety of NASA missions in space operations, exploration and aeronautics. The work presented will focus on the development of advanced inspection systems to detect critical flaws in both metallic and non-metallic materials and structures for aerospace applications. The emphasis is on increasing the performance of inspection systems to provide defect detection and quantitative characterization of the material state. LaRC NDE utilizes expertise in computational ultrasonic, thermal and eddy current simulations to reduce measured responses to size and locations of flaws, establish technique limitations and optimize performance. This presentation will highlight research into five strategic areas: (1) The development of novel solutions using state-of-the-art NDE technologies such as eddy current, ultrasound, thermography and x-ray computed tomography; (2) Research in the development of unique NDE technologies such as terahertz, wavefield imaging and nonlinear ultrasound; (3) The application of both computational and analytic models to NDE problems; (4) The development of advanced analytic methods to interpret large complex data sets; and (5) Advanced methods of applying and interrogating sensors for structural health monitoring.

K Elliott Cramer↗

NASA NTRSDate not supplied

An Overview of Research in Nondestructive Evaluation at the National Aeronautics and Space Administration’s Langley Research Center

NDE↗

NASA NTRS2010

Development and Application of Wide Bandwidth Magneto-Resistive Sensor Based Eddy Current Probe

The integration of magneto-resistive sensors into eddy current probes can significantly expand the capabilities of conventional eddy current nondestructive evaluation techniques. The room temperature solid-state sensors have typical bandwidths in the megahertz range and resolutions of tens of microgauss. The low frequency sensitivity of magneto-resistive sensors has been capitalized upon in previous research to fabricate very low frequency eddy current sensors for deep flaw detection in multilayer conductors. In this work a modified probe design is presented to expand the capabilities of the device. The new probe design incorporates a dual induction source enabling operation from low frequency deep flaw detection to high frequency high resolution near surface material characterization. Applications of the probe for the detection of localized near surface conductivity anomalies are presented. Finite element modeling of the probe is shown to be in good agreement with experimental measurements.

Wincheski, Russell A.↗

DOE OSTI2021

Nondestructive Evaluation (NDE) of Cable Moisture Exposure using Frequency Domain Reflectometry (FDR)

This Pacific Northwest National Laboratory (PNNL) milestone report assesses the capability of frequency domain reflectometry (FDR) to determine electrical cable submergence using PNNL’s Accelerated and Real-Time Environmental Nodal Assessment (ARENA) cable/motor test bed. This work includes a review of relevant literature as well as experimental tests. Nuclear power facilities have experienced various electrical cable failures related to water exposure. The current industry response involves actions to de-water cable vaults, manholes, and other cable locations. These efforts require considerable expenditure of resources, which makes it desirable for the industry to have information on cable condition and history regarding their submergence and water exposure (Mantey 2012). Two tests that are gaining favor within the nuclear industry are time-domain reflectometry (TDR) and FDR. These are low-voltage nondestructive tests that can be applied at a cable end. Testing from the cable end is important because local inspection along the cable length is very difficult due to cables being routed within trays, conduits, underground, and through walls. Both TDR and FDR techniques have been shown to locate cable insulation damage due to thermal, radiation, and mechanical damage. FDR measurements are also more sensitive than TDR to temperature changes, low-bend radius bends, and cable contact with various materials, including conductive materials like steel and water. This work evaluates the feasibility to extend FDR testing to characterizing whether an electrical cable is submerged or not and where it may be submerged using PNNL’s ARENA cable/motor test bed.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗