Total Unwrapped Phase-Based Diagnosis of Wall Thinning in Nuclear Power Plants Secondary Piping Structures
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42 ENGINEERING↗
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First atomic weapons following WWII were detonated 75 years ago Operation Crossroads kicks off era of testing Los Alamos-created weapons [Slides]
It was time to test. After the Los Alamos-created atomic bombs helped end World War II, the no-longer-secret Lab transitioned into an era of weapons testing, starting 75 years ago with Operation Crossroads with the goal of studying nuclear weapons’ effects on warships. In August 1945, U.S. Senator Brien McMahon, who later authored the Atomic Energy Act of 1946, said: “In order to test the destructive powers of the atomic bomb against naval vessels, I would like to see these (Japanese naval) ships taken to sea and an atomic bomb dropped on them. The resulting explosion should prove to us just how effective the atomic bomb is when used against the giant naval ships.”
45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
Nuclear Testing and the Joint Task Force System
During the 1940s, 50s, and early 60s, the United States conducted eight nuclear test operations in the far reaches of the Pacific Ocean. These operations were possible only because of a military command and control organization, the joint task force. Commanded by the Army Navy, and Air Force on a rotating basis, each of the seven JTFs provided the means by which the thousands of ships, planes, material, and personnel were moved over thousands of miles of ocean. The first task force, JTF-1, was created to test the destructive effects of the Fat Man bomb on Naval vessels at Bikini Atoll in the summer of 1946. Commanded by Vice Admiral William “Spike” Blandy, JTF-1 was a purely military operation supported by the MED. Never meant to be a permanent organization, JTF-1 was dissolved soon after completing its mission.
99 GENERAL AND MISCELLANEOUS↗
Robustness and printed sensor qualification
A limiting factor of additive manufactured (AM) sensors for in-pile applications is the development of appropriate interconnection and packaging strategies that can maintain reliable performance in extreme environments. Failure mechanisms in these harsh conditions could include, but not limited to, materials interaction (i.e., intermetallic formation) and coefficient of thermal expansion (CTE) mismatch between the individual components of the sensors. To mitigate premature failure and enable the successful sustained operation of AM sensors, non-destructive qualification tests are used as an intermediate process control step used for verifying robustness and reliability of the sensor before they are deployed. A materials system of interest is the use of barium strontium titanium oxide (BST) films on stainless steel 316L (SS316L) substrate. Due to BST’s high dielectric constant and tunable dielectric properties, there is an interest for its application as an insulation/encapsulation layer for capacitive strain gauges when printed on structural materials. Previous work on the BST/SS316L material system, however, showed that the BST cracks when exposed to temperatures up to 600 °C due to CTE mismatch between the printed BST film and the metallic substrate. When comparing different fabrication techniques, less surface cracking was observed in the samples that deposited thinner (i.e., 2-20 μm) than samples that were thicker (i.e., 135 µm – 300 µm). The objective of this report is to establish a qualification process that will determine and address any challenges (i.e., mechanical failure of thick prints) of the AM sensor prior to its application in experimental tests. To demonstrate the qualification process in this report, laser spallation and uniaxial tensile tests using dynamic and quasi-static loading, respectively, will be discussed.
36 - MATERIALS SCIENCE↗
Modified chemiluminescent NO analyzer accurately measures NOX
Installation of molybdenum nitric oxide (NO)-to-higher oxides of nitrogen (NOx) converter in chemiluminescent gas analyzer and use of air purge allow accurate measurements of NOx in exhaust gases containing as much as thirty percent carbon monoxide (CO). Measurements using conventional analyzer are highly inaccurate for NOx if as little as five percent CO is present. In modified analyzer, molybdenum has high tolerance to CO, and air purge substantially quenches NOx destruction. In test, modified chemiluminescent analyzer accurately measured NO and NOx concentrations for over 4 months with no denegration in performance.
Summers, R. L.↗
Design and fabrication of a stringer stiffened discrete-tube actively cooled panel for a hypersonic aircraft
A 0.61 x 1.22 m (2 x 4 ft) test panel was fabricated and delivered to the Langley Research Center for assessment of the thermal and structural features of the optimized panel design. The panel concept incorporated an aluminum alloy surface panel actively cooled by a network of discrete, parallel, redundant, counterflow passage interconnected with appropriate manifolding, and assembled by adhesive bonding. The cooled skin was stiffened with a mechanically fastened conventional substructure of stringers and frames. A 40 water/60 glycol solution was the coolant. Low pressure leak testing, radiography, holography and infrared scanning were applied at various stages of fabrication to assess integrity and uniformity. By nondestructively inspecting selected specimens which were subsequently tested to destruction, it was possible to refine inspection standards as applied to this cooled panel design.
Anthony, F. M.↗
Evaluation of ceramics for stator applications: Gas turbine engines interim report. Stator fabrication and evaluation
The objective was to assess current ceramic materials, fabrication processes, reliability prediction, and stator durability when subjected to simulated automotive gas turbine engine operating conditions. Ceramic one-piece stators were fabricated of two materials, silicon nitride and silicon carbide, using two near-net-shape processes, slip casting and injection molding. Non-destructive evaluation tests were conducted on all stators identifying irregularities which could contribute to failures under durability testing. Development of the test rig and automatic control system for repeatably controlling air flow rate and temperature over a highly transient durability duty cycle is discussed. Durability results are presented for repeated thermal cycle testing of the ceramic one-piece stators. Two duty cycles were used, encompassing the temperature ranges of 704 to 1204 C (1300 to 2200 F) and 871 to 1371 C (1600 to 2500 F). Tests were conducted on 28 stators, accumulating 135,551 cycles in 2441 hours of hot testing. Cyclic durability for the ceramic one-piece stator was demonstrated to be in excess of 500 hours, accumulating over 28,850 thermal cycles. Ceramic interface forces were found to be the significant factor in limiting stator life rather than the scatter in material strength properties or the variation in component defects encountered.
Arnon, N.↗
Sealed silica pressure ampoules for crystal growth
The properties of vitreous silica and the mechanics of thick walled pressure vessels are reviewed with regard to the construction of sealed silica crucibles such as are used in the growth of mercury-cadmium telluride crystals. Data from destructive rupture tests are reported, failure modes discussed, and recommendations for design given. Ordinary commercial clear vitreous silica from flame fused quartz can withstand a surface stress of 20 MPa or more in this application.
Holland, L. R.↗
List of Preferred Electronic Parts
Components passed stringent qualification tests tabulated and described. Destructive and nondestructive qualification testing confirmed parts capable of withstanding spacecraft environments without excessive degradation and have stable characteristics during operating lives. Testing assessed effects of electrical, environmental, and mechanical stresses in various levels and time durations.
Covey, R. E.↗
Onorbit electron beam welding experiment definition
The proposed experiment design calls for six panels to be welded, each having unique characteristics selected to yield specific results and information. The experiment is completely automated and the concept necessitated the design of a new, miniaturized, self-contained electron beam (EB) welding system, for which purpose a separate IR and D was funded by the contractor, Martin Marietta Corporation. Since future tasks beyond the proposed experiment might call for astronauts to perform hand-held EB gun repairs or for the gun to be interfaced with a dexterous robot such as the planned flight telerobotic servicer (FTS), the EB gun is designed to be dismountable from the automated system. In the experiment design, two separate, identical sets of weld panels will be welded, one on earth in a vacuum chamber and the other onorbit in the aft cargo bay of an orbiter. Since the main objective of the experiment is to demonstrate that high quality welds can be achieved under onorbit conditions, the welds produced will be subjected to a wide range of discriminating non-destructive Q.C. procedures and destructive physical tests. However, advantage will be taken of the availability of a fairly large quantity of welded material in the two series of welded specimens to widen the circle of investigative talent by providing material to academic and scientific institutions for examination.
William H. Hooper↗
Combining high performance simulation, data acquisition, and graphics display computers
Issues involved in the continuing development of an advanced simulation complex are discussed. This approach provides the capability to perform the majority of tests on advanced systems, non-destructively. The controlled test environments can be replicated to examine the response of the systems under test to alternative treatments of the system control design, or test the function and qualification of specific hardware. Field tests verify that the elements simulated in the laboratories are sufficient. The digital computer is hosted by a Digital Equipment Corp. MicroVAX computer with an Aptec Computer Systems Model 24 I/O computer performing the communication function. An Applied Dynamics International AD100 performs the high speed simulation computing and an Evans and Sutherland PS350 performs on-line graphics display. A Scientific Computer Systems SCS40 acts as a high performance FORTRAN program processor to support the complex, by generating numerous large files from programs coded in FORTRAN that are required for the real time processing. Four programming languages are involved in the process, FORTRAN, ADSIM, ADRIO, and STAPLE. FORTRAN is employed on the MicroVAX host to initialize and terminate the simulation runs on the system. The generation of the data files on the SCS40 also is performed with FORTRAN programs. ADSIM and ADIRO are used to program the processing elements of the AD100 and its IOCP processor. STAPLE is used to program the Aptec DIP and DIA processors.
Hickman, Robert J.↗
High-power hydrogen arcjet performance
A hydrogen arcjet was operated at power levels ranging from 5 to 30 kW with three different nozzle geometries. Test results using all three nozzle geometries are reported and include variations of specific impulse with flow rate, and thrust with power. Geometric variables investigated included constrictor diameter, length, and diverging exit angle. The nozzle with a constrictor diameter of 1.78 mm and divergence angle of 20 deg was found to give the highest performance. A specific impulse of 1460 s was attained with this nozzle at a thrust efficiency of 29.8 percent. The best efficiency measured was 34.4 percent at a specific impulse of 1045 s. Post test examination of the cathode showed erosion after 28 hours of operation to be small, and limited to the conical tip where steady state arc attachment occurred. Each nozzle was tested to destruction.
Haag, Thomas W.↗
High-power hydrogen arcjet performance
A hydrogen arcjet was operated at power levels ranging from 5 to 30 kW with three different nozzle geometries. Test results using all three nozzle geometries are reported and include variations of specific impulse with flow rate, and thrust with power. Geometric variables investigated included constrictor diameter, length, and diverging exit angle. The nozzle with a constrictor diameter of 1.78 mm and divergence angle of 20 degrees was found to give the highest performance. A specific impulse of 1460 s was attained with this nozzle at a thrust efficiency of 29.8 percent. The best efficiency measured was 34.4 percent at a specific impulse of 1045 s. Post test examination of the cathode showed erosion after 28 hours of operation to be small, and limited to the conical tip where steady state arc attachment occurred. Each nozzle was tested to destruction.
Haag, Thomas W.↗
Investigations of Air-cooled Turbine Rotors for Turbojet Engines II : Mechanical Design, Stress Analysis, and Burst Test of Modified J33 Split-disk Rotor / Richard H. Kemp and Merland L. Moseson
A full-scale J33 air-cooled split turbine rotor was designed and spin-pit tested to destruction. Stress analysis and spin-pit results indicated that the rotor in a J33 turbojet engine, however, showed that the rear disk of the rotor operated at temperatures substantially higher than the forward disk. An extension of the stress analysis to include the temperature difference between the two disks indicated that engine modifications are required to permit operation of the two disks at more nearly the same temperature level.
TURBINES - WHEELS, DISK - STRENGTH↗
HYPERSAMP
Hypergeometric Attribute Sampling System Based on Risk and Fraction Defective (HYPERSAMP) computer program demonstrates attribute sampling system developed to determine minimum sample size required for any preselected value for consumer's risk and fraction of nonconforming units. Used in place of MIL-STD-105E sampling plans when minimum sample size desirable, such as when tests are destructive or expensive. Written for IBM PC-compatible computers.
Desalvo, Louis J.↗
Static measurement of the thickness of the ablative coating of the solid rocket boosters
The Solid Rocket Boosters (SRB's) used to launch the Space Shuttle are coated with a layer of ablative material to prevent thermal damage when they reenter the earth's atmosphere. The coating consists of a mixture of cork, glass, and resin. A new coating (Marshall Convergent Coating, MCC-2) was recently developed that is environmentally complaint. The coating must meet certain minimum thickness standards in order to protect the SRB. The coating is applied by a robot controlled nozzle that moves from the bottom to top, as the rocket part rotates on a table. Several coats are applied, building up to the desired thickness. Inspectors do a limited amount of destructive 'wet' testing. This involves an inspector inserting a rod in the wet coating and removing the rod. This results in a hole that, of course, must be patched later. The material is cured and the thickness is measured. There is no real-time feedback as the coating is being applied. Although this might seem like the best way to control thickness, the problems with 'blowback' (reflected material covering the sensor) are formidable, and have not been solved. After the thermal coating is applied, a protective top coat is applied. The SRB part is then placed in a oven and baked to harden the surface. The operations personnel then measure the thickness of the layer using the Kaman 7200 Displacement Measuring System. The probe is placed on the surface. One person (the inspector) reads the instrument, while another(the technician) records the thickness. Measurements are taken at one foot intervals. After the measurements are taken, the number of low readings is tabulated. If more than 10 percent of the points fall below the minimum value, there is a design review, and the part may be stripped of coating, and a new coating is applied. There is no other analysis.
Harrison, Harry C.↗
Shearography for Non-destructive Inspection with applications to BAT Mask Tile Adhesive Bonding and Specular Surface Honeycomb Panels
The applicability of shearography techniques for non-destructive evaluation in two unique application areas is examined. In the first application, shearography is used to evaluate the quality of adhesive bonds holding lead tiles to the B.4T gamma ray mask for the NASA Swift program. Using a vibration excitation, the more poorly bonded tiles are readily identifiable in the shearography image. A quantitative analysis is presented that compares the shearography results with a destructive pull test measuring the force at bond failure. The second application is to evaluate the bonding between the skin and core of a honeycomb structure with a specular (mirror-like) surface. In standard shearography techniques, the object under test must have a diffuse surface to generate the speckle patterns in laser light, which are then sheared. A novel configuration using the specular surface as a mirror to image speckles from a diffuser is presented, opening up the use of shearography to a new class of objects that could not have been examined with the traditional approach. This new technique readily identifies large scale bond failures in the panel, demonstrating the validity of this approach.
Lysak, Daniel B.↗
Shearography for Non-Destructive Evaluation with Applications to BAT Mask Tile Adhesive Bonding and Specular Surface Honeycomb Panels
In this report we examine the applicability of shearography techniques for nondestructive inspection and evaluation in two unique application areas. In the first application, shearography is used to evaluate the quality of adhesive bonds holding lead tiles to the BAT gamma ray mask for the NASA Swift program. By exciting the mask with a vibration, the more poorly bonded tiles can be distinguished by their greater displacement response, which is readily identifiable in the shearography image. A quantitative analysis is presented that compares the shearography results with a destructive pull test measuring the force at bond failure. Generally speaking, the results show good agreement. Further investigation would be useful to optimize certain test parameters such as vibration frequency and amplitude. The second application is to evaluate the bonding between the skin and core of a honeycomb structure with a specular (mirror-like) surface. In standard shearography techniques, the object under test must have a diffuse surface to generate the speckle patterns in laser light, which are then sheared. A novel configuration using the specular surface as a mirror to image speckles from a diffuser is presented, opening up the use of shearography to a new class of objects that could not have been examined with the traditional approach. This new technique readily identifies large scale bond failures in the panel, demonstrating the validity of this approach. For the particular panel examined here, some scaling issues should be examined further to resolve the measurement scale down to the very small size of the core cells. In addition, further development should be undertaken to determine the general applicability of the new approach and to establish a firm quantitative foundation.
Lysak, Daniel B.↗