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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Binomial Test Method for Determining Probability of Detection Capability for Fracture Critical Applications

The capability of an inspection system is established by applications of various methodologies to determine the probability of detection (POD). One accepted metric of an adequate inspection system is that for a minimum flaw size and all greater flaw sizes, there is 0.90 probability of detection with 95% confidence (90/95 POD). Directed design of experiments for probability of detection (DOEPOD) has been developed to provide an efficient and accurate methodology that yields estimates of POD and confidence bounds for both Hit-Miss or signal amplitude testing, where signal amplitudes are reduced to Hit-Miss by using a signal threshold Directed DOEPOD uses a nonparametric approach for the analysis or inspection data that does require any assumptions about the particular functional form of a POD function. The DOEPOD procedure identifies, for a given sample set whether or not the minimum requirement of 0.90 probability of detection with 95% confidence is demonstrated for a minimum flaw size and for all greater flaw sizes (90/95 POD). The DOEPOD procedures are sequentially executed in order to minimize the number of samples needed to demonstrate that there is a 90/95 POD lower confidence bound at a given flaw size and that the POD is monotonic for flaw sizes exceeding that 90/95 POD flaw size. The conservativeness of the DOEPOD methodology results is discussed. Validated guidelines for binomial estimation of POD for fracture critical inspection are established.

Generazio, Edward R.↗
NASA NTRS1973

Acoustic emission testing of 12-nickel maraging steel pressure vessels

Acoustic emission data were obtained from three point bend fracture toughness specimens of 12-nickel maraging steel, and two pressure vessels of the same material. One of the pressure vessels contained a prefabricated flaw which was extended and sharpened by fatigue cycling. It is shown that the flawed vessel had similar characteristics to the fracture specimens, thereby allowing estimates to be made of its nearness to failure during a proof test. Both the flawed and unflawed pressure vessel survived the proof pressure and 5 cycles to the working pressure, but it was apparent from the acoustic emission response during the proof cycle and the 5 cycles to the working pressure that the flawed vessel was very near failure. The flawed vessel did not survive a second cycle to the proof pressure before failure due to flaw extension through the wall (causing a leak).

Dunegan, H. L.↗
NASA NTRS1988

NDE detectability of fatigue-type cracks in high-strength alloys: NDI reliability assessments

This program was conducted to generate quantitative flaw detection capability data for the nondestructive evaluation (NDE) techniques typically practiced by aerospace contractors. Inconel 718 and Haynes 188 alloy test specimens containing fatigue flaws with a wide distribution of sizes were used to assess the flaw detection capabilities at a number of contractor and government facilities. During this program 85 inspection sequences were completed presenting a total of 20,994 fatigue cracks to 53 different inspectors. The inspection sequences completed included 78 liquid penetrant, 4 eddy current, and 3 ultrasonic evaluations. The results of the assessment inspections are presented and discussed. In generating the flaw detection capability data base, procedures for data collection, data analysis, and specimen care and maintenance were developed, demonstrated, and validated. The data collection procedures and methods that evolved during this program for the measurement of flaw detection capabilities and the effects of inspection variables on performance are discussed. The Inconel 718 and Haynes 188 test specimens that were used in conducting this program and the NDE assessment procedures that were demonstrated, provide NASA with the capability to accurately assess the flaw detection capabilities of specific inspection procedures being applied or proposed for use on current and future fracture control hardware program.

Christner, Brent K.↗
NASA NTRS2000

A Strip-Yield Model for Predicting the Growth of Part-Through Cracks Under Cyclic Loading

Flaws exist in aircraft structures due to manufacturing operations and material defects. Under variable amplitude cyclic loading, these flaws grow as part-through cracks reducing the residual strength of structural components. To meet damage tolerant design requirements, accurate flaw growth predictions are needed which account for continual changes in crack shape as well as crack growth retardation and acceleration. Predicting the growth of part-through cracks under cyclic loading using an innovative and computationally efficient model is the focus of the research summarized in this report. In this research effort, a slice synthesis methodology was developed and used to construct a modified strip-yield model for the part-through semi-elliptical surface flaw, enabling prediction of plasticity-induced closure along the crack front and subsequent fatigue crack growth under constant amplitude and variable amplitude loading. While modeling the plasticity-induced closure in a part-through flaw may be performed using three dimensional elastic-plastic finite element analysis, this type of effort is impractical from an engineering perspective. A modified strip-yield model similar to that used in FASTRAN for part-through flaws is a much needed engineering design tool, particularly when computational resources are limited.

Daniewicz, S. R.↗
NASA NTRS1994

Detection of Cracks at Welds in Steel Tubing Using Flux Focusing Electromagnetic Probe

The inspection of weldments in critical pressure vessel joints is a major concern in the nuclear power industry. Corrosive environments can speed the fatigue process and access to the critical area is often limited. Eddy current techniques have begun to be used to help overcome these obstacles [1]. As direct contact and couplants are not required, remote areas can be inspected by simply snaking an eddy current coil into the intake tube of the vessel. The drawback of the eddy current method has been the high sensitivity to small changes in the conductivity and permeability of the test piece which are known to vary at weldments [1]. The flaw detection mechanism of the flux focusing electromagnetic probe can help alleviate these difficulties and provide a unique capability for detecting longitudinal fatigue cracks in critical tube structures. The Flux Focusing Electromagnetic Flaw Detector, originally invented for the detection of fatigue and corrosion damage in aluminum plates [2-3], has been adapted for use in testing steel tubing for longitudinal fatigue cracks. The modified design allows for the probe to be placed axisymmetrically into the tubing, inducing eddy currents in the tube wall. The pickup coil of the probe is fixed slightly below the primary windings and is rotated 90 so that its axis is normal to the tube wall. The magnetic flux of the primary coil is focused through the use of ferromagnetic material so that in the absence of fatigue damage there will be no flux linkage with the pickup coil. The presence of a longitudinal fatigue crack will cause the eddy currents induced in the tube wall to flow around the flaw and directly under the pickup coil. The magnetic field associated with these currents will then link the pickup coil and an unambiguous increase in the output voltage of the probe will be measured. The use of the flux focusing electromagnetic probe is especially suited for the detection of flaws originating at or near tube welds. The probe is shown to discriminate against signals due solely to the weld joint so that flaw signals are not hidden in the background in these locations. Experimental and finite element modeling results are presented for the flaw detection capabilities of the probe in stainless steel tubes.

Wincheski, Buzz↗
NASA NTRS2012

Research and Development of Automated Eddy Current Testing for Composite Overwrapped Pressure Vessels

Eddy current testing (ET) was used to scan bare metallic liners used in the fabrication of composite overwrapped pressure vessels (COPVs) for flaws which could result in premature failure of the vessel. The main goal of the project was to make improvements in the areas of scan signal to noise ratio, sensitivity of flaw detection, and estimation of flaw dimensions. Scan settings were optimized resulting in an increased signal to noise ratio. Previously undiscovered flaw indications were observed and investigated. Threshold criteria were determined for the system software's flaw report and estimation of flaw dimensions were brought to an acceptable level of accuracy. Computer algorithms were written to import data for filtering and a numerical derivative filtering algorithm was evaluated.

Carver, Kyle L.↗
NASA NTRSDate not supplied

TPSAS-NF1676L-32030-DND

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA?s Advanced Composites Project, a public-private partnership between government, universities and industry, seeks to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites is one of the three focused research areas of the project. One deliverable of the project is to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publically available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate polymer matrix composite (PMC) structures. The Handbook will reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. The Handbook will include an NDE Guidance Matrix that provides an applicability rating for NDE techniques as they apply to given flaw types. NDE techniques will include, but is not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types will include, but are not limited to porosity, delamination, voids, AFP defects and impact damage. The Handbook will contain details that support the applicability rating including, but not limited to, specimen details, inspection parameters, data analysis techniques, inspection efficiency (speed & cost), and limitations. This presentation will describe key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members.

Patricia A Howell↗
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↗
NASA NTRS1972

Evaluation and optimization of the advanced signal counting techniques on weldments

The signal counting technique with the Delta ultrasonic method is evaluated and optimized for flaw detection in aluminum welds. A comparison is made between the counting and conventional amplitude-gate methods to detect flaws. No conclusion is drawn on the sensitivity of these two methods to detect flaws when the mismatch at the welds is small (25 mils or less). When the mismatch is 25 mils or more, the signal counting method is more sensitive. Of the 24 welded specimens, 50 flaws were found by X-ray inspection and 59 by the Delta method. On 1/4-inch thick welds, X-ray is equal to or slightly more sensitive than Delta method, but on the 1/2-inch thick welds Delta ultrasonic appears more sensitive in flaw detection.

Yee, B. G. W.↗
NASA NTRS1973

Detection of fatigue cracks by nondestructive testing methods

The effectiveness was assessed of various NDT methods to detect small tight cracks by randomly introducing fatigue cracks into aluminum sheets. The study included optimizing NDT methods calibrating NDT equipment with fatigue cracked standards, and evaluating a number of cracked specimens by the optimized NDT methods. The evaluations were conducted by highly trained personnel, provided with detailed procedures, in order to minimize the effects of human variability. These personnel performed the NDT on the test specimens without knowledge of the flaw locations and reported on the flaws detected. The performance of these tests was measured by comparing the flaws detected against the flaws present. The principal NDT methods utilized were radiographic, ultrasonic, penetrant, and eddy current. Holographic interferometry, acoustic emission monitoring, and replication methods were also applied on a reduced number of specimens. Generally, the best performance was shown by eddy current, ultrasonic, penetrant and holographic tests. Etching provided no measurable improvement, while proof loading improved flaw detectability. Data are shown that quantify the performances of the NDT methods applied.

Anderson, R. T.↗
NASA NTRS1974

Stress intensity factors for deep cracks emanating from the corner formed by a hole intersecting a plate surface

A technique consisting of a marriage between stress freezing photoelasticity and a numerical method was used to obtain stress intensity factors for natural cracks emanating from the corner at which a hole intersects a plate surface. Geometrics studied were: crack depth to thickness ratios of approximately 0.2, 0.5, and 0.75; crack depth to crack length ratios of approximately 1.0 to 2.0. All final crack geometries were grown under monotonic loading and growth was not self similar with most of the growth occurring through the thickness under remote extension. Stress intensity plate surface K sub s factors were determined at the intersection of the flaw border with the plate surface K sub s and with the edge of the hole K sub h. Results showed that for the relatively shallow flaws K sub h approximately equal to 1.5 K sub s, for the moderately deep flaws K sub h approximately equal to K sub s, and for the deep flaws K sub h approximately equal to 0.5 K sub s, revealing a severe sensitivity of K to flaw geometry.

Mcgowan, J. J.↗
NASA NTRS1973

Reliability after inspection

Flaws are occasionally overlooked during non-destructive inspections, and consequently the products are not 100 percent reliable. The quantitative relationships among the probability of having manufacturing defects, the probability of detecting a flaw, and final reliability are established. Several specific situations are considered: where a flaw might be present; where a random number of flaws are randomly scattered throughout the piece; where some parts of the product are not accessible for inspection; and a general case where various portions are more easily inspected than others, more or less likely to contain flaws than others, or are not inspectable while other portions are.

Davidson, J. R.↗
NASA NTRS1976

Stress intensity factors for deep cracks emanating from the corner formed by a hole intersecting a plate surface

The stress intensity factors (SIFs) at the end points of flaws emanating from the corner formed by the intersection of a plate with a hole were determined using stress freezing photoelasticity and a numerical technique known as the Taylor series correction method to extract the SIF values from the photoelastic data. The geometries studied were crack depth to thickness ratios of about 0.2, 0.5, and 0.75; crack depth to crack length ratios of about 1.0 to 2.0; and crack length to hole radius ratios of about 0.5 to 2.0. The SIFs were determined at the intersection of the flaw border with the plate surface (KS) and with the edge of the hole (KH). It is shown that extension of a crack emanating from a corner of intersection of a hole with a plate under monotonically increasing load is not self-similar and that as the flaw depth increases, KH decreases and KS increases. Existing theories and design criteria significantly overestimate the SIF at both the hole and the surface except for shallow flaws at the hole and deep flaws at the surface.

Mcgowan, J. J.↗
NASA NTRS1977

Techniques for increasing boron fiber fracture strain

Improvement in the strain-to-failure of CVD boron fibers is shown possible by contracting the tungsten boride core region and its inherent flaws. The results of three methods are presented in which etching and thermal processing techniques were employed to achieve core flaw contraction by internal stresses available in the boron sheath. After commercially and treatment induced surface flaws were removed from 203 micrometers (8 mil) fibers, the core flaw was observed to be essentially the only source of fiber fracture. Thus, fiber strain-to-failure was found to improve by an amount equal to the treatment induced contraction on the core flaw. Commercial feasibility considerations suggest as the most cost effective technique that method in which as-produced fibers are given a rapid heat treatment above 700 C. Preliminary results concerning the contraction kinetics and fracture behavior observed are presented and discussed both for high vacuum and argon gas heat treatment environments.

Dicarlo, J. A.↗
NASA NTRS1977

Techniques for increasing boron fiber fracture strain

Improvement in the strain-to-failure of chemical-vapor-deposition boron fibers is shown possible by contracting the tungsten boride core region and its inherent flaws. Results of three methods are presented in which etching and thermal-processing techniques were employed to achieve core flaw contraction by internal stresses available in the boron sheath. After commercially and treatment-induced surface flaws were removed from 203-micron (8-mil) fibers, the core flaw was observed to be essentially the only source of fiber fracture. Thus, fiber strain-to-failure was found to improve by an amount equal to the treatment-induced contraction on the core flaw. To date, average fracture strains and stresses greater than 1.4% and 5.5 GN/sq m (800 ksi), respectively, have been achieved. Commercial feasibility considerations suggest as the most cost-effective technique that method in which as-produced fibers are given a rapid heat treatment above 700 C. Preliminary results concerning the contraction kinetics and fracture behavior observed with this technique are presented and discussed for both high-vacuum and argon-gas heat-treatment environments.

Dicarlo, J. A.↗
NASA NTRS1983

Statistical Analysis of a Debugging Model

Suppose that a system is undergoing a sequence of trials and design changes in an effort to find and eliminate design flaws in the system. Specifically, suppose that each trial is classified as an assignable cause failure (if the failure is due to one or more design flaws), an inherent failure (if the failure is not due to a design flaw), or a success. After each assignable cause failure, the design flaws that caused the failure are removed. In the case of statistically independent and identical design flaws, a probabilistic model is developed to describe this debugging process. Explicit expressions are obtained for the distributions of the important random variables and for the important measures of reliability. Statistical methods are developed for estimating the parameters of the model from accumulated test data.

Siegrist, K.↗
NASA NTRS1986

Fracture analysis of radial scientific instrument module registration fittings of the space telescope

Various pieces of the registration fittings for the Radial Scientific instrument (SI) module of the Space Telescope were examined from a fracture mechanics point of view and deemed to be fail-safe or else have had maximum allowable flaw sizes specified for them. The results of these analyses are summarized in tabular form. In many instances the applied stress levels were so low that the threshold stress intensity factor range was never reached. In most of the others the allowable flaw sizes were large enough to be detected by visual inspection. However, for some parts, such as the flexures connecting the aluminum cover to the ball retainer in the fitting at point A, the flaw sizes were rather small. Eddy current tests are capable of detecting flaws of this size (0.022 inches x 0.1 inches), so for those which have been so tested these small flaws should represent no danger of going undetected. In every instance approximations were made to err on the conservative side. These were pointed out in the discussions of the analyses for each fitting. One conservative approximation that was not mentioned, however, is the fact that retardation was not included in the crack propagation computations.

Springfield, C. W., Jr.↗
NASA NTRS1989

Formal verification of a fault tolerant clock synchronization algorithm

A formal specification and mechanically assisted verification of the interactive convergence clock synchronization algorithm of Lamport and Melliar-Smith is described. Several technical flaws in the analysis given by Lamport and Melliar-Smith were discovered, even though their presentation is unusally precise and detailed. It seems that these flaws were not detected by informal peer scrutiny. The flaws are discussed and a revised presentation of the analysis is given that not only corrects the flaws but is also more precise and easier to follow. Some of the corrections to the flaws require slight modifications to the original assumptions underlying the algorithm and to the constraints on its parameters, and thus change the external specifications of the algorithm. The formal analysis of the interactive convergence clock synchronization algorithm was performed using the Enhanced Hierarchical Development Methodology (EHDM) formal specification and verification environment. This application of EHDM provides a demonstration of some of the capabilities of the system.

Rushby, John↗