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At least 235 records · Page 13

Comparison of In-situ Near Infrared Melt Pool Imagery to Optical Microscopy Measurements

Additive manufacturing (AM) is a rapidly growing technology. An area of major importance is the integrity and repeatability of AM parts. The goal is to reduce obstacles to certify AM built parts to allow for use in critical aerospace applications. In-situ nondestructive evaluation sensors can be used for build assessment and can potentially play a key role in certifying AM parts. For example, melt pool features are understood to have a strong correlation to microstructural defects and the use of a near infrared (NIR) camera can be used to record the melt pool, cooling areas, and temperature gradients during the build. This work explores the use of a low cost NIR camera to obtain single line track imagery of the Ti-6Al-4V melt pools for various processing parameters. The NIR camera is radiometrically calibrated and configured in-line with the laser source to obtain high resolution imagery of the melt pool shape and dynamics. The challenge to measure melt pool shapes is to identify the transition points between the metal solid to liquid phase. Factors for melt pool measurements such as thermal camera pixel resolution, surface emissivity, and blurring due to the laser beam movement are discussed. Lastly, the melt pool imagery are compared to optical microscopy measurements for validation.

additive manufacturing↗

Three-Axis Distributed Fiber Optic Strain Measurement in 3D Woven Composite Structures

Recent advancements in composite materials technologies have broken further from traditional designs and require advanced instrumentation and analysis capabilities. Success or failure is highly dependent on design analysis and manufacturing processes. By monitoring smart structures throughout manufacturing and service life, residual and operational stresses can be assessed and structural integrity maintained. Composite smart structures can be manufactured by integrating fiber optic sensors into existing composite materials processes such as ply layup, filament winding and three-dimensional weaving. In this work optical fiber was integrated into 3D woven composite parts at a commercial woven products manufacturing facility. The fiber was then used to monitor the structures during a VARTM manufacturing process, and subsequent static and dynamic testing. Low cost telecommunications-grade optical fiber acts as the sensor using a high resolution commercial Optical Frequency Domain Reflectometer (OFDR) system providing distributed strain measurement at spatial resolutions as low as 2mm. Strain measurements using the optical fiber sensors are correlated to resistive strain gage measurements during static structural loading. Keywords: fiber optic, distributed strain sensing, Rayleigh scatter, optical frequency domain reflectometry

Castellucci, Matt↗

OH radical measurements by optical absorption spectroscopy

The long path absorption spectroscopy (LPA) measurement of OH utilizes the strong UV absorption spectrum of the molecule with well resolved rotational lines around 308 nm. The light source consists of an Ar ion laser pumped CW dye laser, the output of which is frequency doubled to emit a spectrally smooth light profile of 0.1 nm FWHM at 308 nm. This is considerably broader than the sharp (0.0018 nm wide) absorption features of OH and also wider than the total spectral region (0.06 nm) scanned around the OH lines. For field measurements a Cassegrain-type telescope expands the small diameter of the original laser beam by a factor of 50 to about a 0.25-m diameter in order to reduce the divergence of the beam as well as its mean photon flux density, thus reducing the maximum self-generated OH concentration to 40,000 cu. cm. The light is passed into the open atmosphere and reflected at about 5 km distance resulting in a 10-km light path length. A telescope focuses the returning light onto the entrance slit of a monochromator the single exit slit of which is replaced by a mechanical scanning device operating at a scan repetition rate of 6.6 KHz. For a typical measurement (1h duration) some 20,000,000 scans are averaged, rendering the contribution of atmospheric turbulence to the spectral noise negligible.

Platt, U.↗

Measuring Bearing-Cage Rotation

Bearing slip measured optically. Concept for measuring rotational speed of bearing cage promises to be simple and accurate. Based on fiber optics, requires no contact between measuring device and bearing, and would not introduce wear.

Roschak, E. J.↗

Optical Air Flow Measurements for Flight Tests and Flight Testing Optical Air Flow Meters

Optical air flow measurements can support the testing of aircraft and can be instrumental to in-flight investigations of the atmosphere or atmospheric phenomena. Furthermore, optical air flow meters potentially contribute as avionics systems to flight safety and as air data systems. The qualification of these instruments for the flight environment is where we encounter the systems in flight testing. An overview is presented of different optical air flow measurement techniques applied in flight and what can be achieved with the techniques for flight test purposes is reviewed. All in-flight optical airflow velocity measurements use light scattering. Light is scattered on both air molecules and aerosols entrained in the air. Basic principles of making optical measurements in flight, some basic optical concepts, electronic concepts, optoelectronic interfaces, and some atmospheric processes associated with natural aerosols are reviewed. Safety aspects in applying the technique are shortly addressed. The different applications of the technique are listed and some typical examples are presented. Recently NASA acquired new data on mountain rotors, mountain induced turbulence, with the ACLAIM system. Rotor position was identified using the lidar system and the potentially hazardous air flow profile was monitored by the ACLAIM system.

Jentink, Henk W.↗

Optical strain measuring techniques for high temperature tensile testing

A number of optical techniques used for the analysis of in-plane displacements or strains are reviewed. The application would be for the high temperature, approximately 1430 C (2600 F), tensile testing of ceramic composites in an oxidizing atmosphere. General descriptions of the various techniques and specifics such as gauge lengths and sensitivities are noted. Also, possible problems with the use of each method in the given application are discussed.

Gyekenyesi, John Z.↗

Assessment of Error in Aerosol Optical Depth Measured by AERONET Due to Aerosol Forward Scattering

We present an analysis of the effect of aerosol forward scattering on the accuracy of aerosol optical depth (AOD) measured by CIMEL Sun photometers. The effect is quantified in terms of AOD and solar zenith angle using radiative transfer modeling. The analysis is based on aerosol size distributions derived from multi-year climatologies of AERONET aerosol retrievals. The study shows that the modeled error is lower than AOD calibration uncertainty (0.01) for the vast majority of AERONET level 2 observations, ~99.53%. Only ~0.47% of the AERONET database corresponding mostly to dust aerosol with high AOD and low solar elevations has larger biases. We also show that observations with extreme reductions in direct solar irradiance do not contribute to level 2 AOD due to low Sun photometer digital counts below a quality control cutoff threshold.

AERONET↗

Optical phase measuring sensors for automated rendezvous and capture

A technique is described for sensing relative spatial orientations of approach and target vehicles, using optical phase mensuration (in the interferometric sense, as opposed to LIDAR), in place of the more conventional intensity, image, or transit time measurements. This approach permits the parameters to be measured with great accuracy with relatively simple, small sensors having no moving components. A suite of sensors operating on this principle can produce all desired data using either active detection on the target or passive retroreflection to the detectors on the approach vehicle. These optical phase measurements can be applied to determine bearing angle (location of the target vehicle in the approach vehicle coordinates), range, and attitude (orientation of the target vehicle with respect to the line-of-sight). The first two quantities require the approach vehicle to project a modulated interference pattern into space. The bearing angle is determined for a selected point on the target by measuring the phase of the interference pattern at that point using either a detector on the target or a retroreflector on the target and a detector at the transmitter. The range is found by measuring differential bearing angles to predetermined relative instrumentation sites. Two interferometers, a coarse and a fine ranger are required to resolve the 2pi ambiguity.

Metheny, Wayne↗

An optical motion measuring system for laterally oscillated fatigue tests

This paper describes an optical system developed for materials testing laboratories at NASA Langley Research Center (LaRC) for high resolution monitoring of the transverse displacement and angular rotation of a test specimen installed in an axial-tension bending machine (ATB) during fatigue tests. It consists of a small laser, optics, a motorized mirror, three photodiodes, electronic detection and counting circuits, a data acquisition system, and a personal computer. A 3-inch by 5-inch rectangular plate attached to the upper grip of the test machine serves as a target base for the optical system. The personal computer automates the fatigue test procedure, controls data acquisition, performs data reduction, and provides user displays. The data acquisition system also monitors signals from up to 16 strain gages mounted on the test specimen. The motion measuring system is designed to continuously monitor and correlate the amplitude of the oscillatory motion with the strain gage signals in order to detect the onset of failure of the composite test specimen. A prototype system has been developed and tested which exceeds the design specifications of +/- 0.01 inch displacement accuracy, and +/- 0.25 deg angular accuracy at a sampling rate of 100 samples per second.

Tripp, John S.↗

Shockwave/Boundary-Layer Interaction Studies Performed in the NASA Langley 20-Inch Mach 6 Air Tunnel

This paper highlights results from a collaborative study performed by The University of Tennessee Space Institute (UTSI) and NASA Langley Research Center on the Shockwave/Boundary-Layer Interaction (SWBLI) generated by a cylindrical protuberance on a flat plate in a Mach 6 flow. The study was performed in the 20-Inch Mach 6 Air Tunnel at NASA Langley Research Center and consisted of two separate entries. In the first entry, simultaneous high-speed schlieren and high-speed pressure-sensitive paint (PSP) imaging – which was performed for the first time in the 20-Inch Mach 6 facility at NASA Langley – were performed as well as simultaneous high-speed schlieren and oil-flow imaging. In the second entry, the model configuration was modified to increase the size of the interaction region. High-speed schlieren and infrared thermography (IR) surface imaging were performed in this second entry. The goal of these tests was to characterize the SBLI in the presence of a laminar, transitional, and turbulent boundary layer using high-speed optical imaging techniques. AoA = sting angle-of-attack (°) dcylinder = cylinder diameter (mm) dtrip = cylindrical tripping element diameter (mm) Δshock = shock stand-off distance (mm) hcylinder = cylinder height (mm) htrip = cylindrical tripping element height (mm) HSS = high-speed schlieren M∞ = freestream Mach number PSP = pressure-sensitive paint Re∞ = freestream unit Reynolds number (m-1) SWBLI = shockwave/boundary-layer interaction θplate = model plate angle (°) Introduction his paper highlights two experimental entries performed in the 20-Inch Mach 6 Air Blowdown Tunnel at NASA Langley Research Center in collaboration with The University of Tennessee Space Institute (UTSI). The purpose of these entries was to characterize the dynamic shockwave/boundary-layer interaction (SWBLI) between a vertical cylinder on a flat plate and laminar, transitional (XSWBLI), and turbulent (SWTBLI) boundary layers with a freestream Mach number of 6 using non-intrusive optical diagnostics. Experiments performed by Murphree et al.1,2 were among the first to specifically characterize XSWBLI induced by a vertical cylinder on a flat plate geometry using several optical measurement techniques. Recent optical studies of XSWBLI phenomenon have been performed by UTSI at Mach 2 in their low-enthalpy blow wind tunnel3-8 and by Texas A&M University and UTSI at Mach numbers of 6 and 7 in their Adjustable Contour Expansion wind tunnel.9 The experiments described in this paper were intended to complement previous studies by expanding the freestream unit Reynolds number range, Re∞, over which the XSWBLI phenomena has been observed. Additionally these experiments, made possible under NASA’s new facility funding model under the Aeronautics Evaluation and Test Capabilities (AETC) project, promoted collaboration between university and NASA researchers. The initial entry in the 20-Inch Mach 6 Air Tunnel at NASA Langley occurred in December of 2016. Originally, testing was to occur in November of 2016 in the 31-Inch Mach 10 Air Tunnel at NASA Langley. This facility was chosen so that the XSWBLI phenomenon could be observed at much higher Mach numbers than had previously been attempted in ground test experiments. The model selected for this experiment, a 10° half-angle wedge with a sharp leading edge (described in detail in section II.B), had previously been used by Danehy et al. [10] for boundary layer transition studies using the nitric oxide planar laser-induced fluorescence (NO PLIF) flow visualization technique. In that work, it was determined that transition could be induced downstream of a single htrip = 1-mm tall, dtrip = 4-mm diameter cylindrical tripping element and that the streamwise location of the transition could be changed for a single Re∞ by changing the model angle-of-attack (AoA) (see Fig. A3 in Ref. [10] for more details). Based on the findings of that work, a decision was made to use the wedge model with the cylindrical tripping element to trip the boundary layer flow ahead of a cylindrical protuberance in order to achieve a XSWBLI. Unfortunately, the 31-Inch Mach 10 facility had been taken offline for repairs in October of 2016 and a decision was made to move the test to the 20-Inch Mach 6 facility. Since the behavior of the boundary layer with the chosen model configuration had not been studied before in that facility and the available test time was limited, the entry was considered to be exploratory and was used to collect spatially-resolved and time-resolved flow and surface visualization data that would be used to inform a second entry. Test techniques included simultaneous high-speed schlieren (HSS) captured at 160 kHz and high-speed pressure sensitive paint captured at 10 kHz as well as oil flow visualization, captured at 750 Hz. The second entry in the 20-Inch Mach 6 facility occurred in June and July of 2017. In this follow-on test, modifications to the wind tunnel model were made based on observations made during the first entry and included removing the cylindrical tripping element, increasing the size of the cylinder used to induce the SWBLI to increase the size of the interaction while simultaneously improving spatial resolution, and using a swept ramp array, similar to that described in Ref. [11], to trip the flow to turbulence. Simultaneous HSS (captured at 140 kHz, 100 kHz, and 40 kHz) and conventional IR thermography (captured at 30 Hz) imaging were performed simultaneously in this follow-on entry. This paper is intended to serve as a summary of the work performed during these two entries, to detail lessons learned from each entry, and to highlight some of the datasets acquired. Details on the experimental setup, model configuration, and techniques used are provided. Papers providing a more rigorous analysis of data acquired during the second entry, including statistical, spectral, and modal decomposition methods, can be found in Refs. [12,13]. An entry examining XSWBLI in the 31-Inch Mach 10 Blowdown Wind Tunnel facility is currently planned for mid-to-late calendar year 2019, pending the success of facility repairs. The work performed and described in this paper and the upcoming entry in the 31-Inch Mach 10 facility at NASA Langley have been made possible by NASA’s new facility funding model under the Aeronautics Evaluation and Test Capabilities (AETC) project. Wind Tunnel Facility All experiments discussed in this paper were performed in the 20-Inch Mach 6 Air Tunnel at NASA Langley Research Center. Specific details pertaining to this facility can be found in Refs. [14,15], with only a brief description of the facility provided here. For both entries, the nominal freestream unit Reynolds number was varied between 1.8×106 m-1 (0.5×106 ft-1) and 26.3×106 m-1 (8×106 ft-1). The nominal stagnation pressure was varied between 0.21 MPa and 3.33 MPa and the nominal stagnation temperature was varied between 480 K and 520 K to achieve the desired Re∞ condition. For all runs, the nominal freestream Mach number was 6. The nearly square test section is 520.7-mm (20.5-inches) wide by 508-mm (20-inches) high. Two 431.8-mm (17-inch) diameter windows made of Corning 7940, Grade 5F schlieren-quality glass serve as the side walls of the tunnel and provide optical access for the high-speed schlieren measurements. A rectangular window made of the same material as the side windows served as the top wall of the test section and provided optical access for the high-speed PSP and oil flow measurements. For the second entry, this top window was replaced with a Zinc Selenide (ZnSe) window with an anti-reflection coating capable of passing IR wavelengths between 8μm and 12μm with greater than 98% transmittance. The model was sting supported by a strut attached to a hydraulic system that allows for the model pitch angle to be adjusted between -5° to +55°. For the first entry, an initial pitch/pause sweep of the model AoA was performed to observe the resulting SWBLI. Ultimately, however, the sting pitch angle for this entry was fixed at +10.0° so that the angle of the top surface of the wedge relative to the streamwise axis of the tunnel (referred to herein as the plate angle, θplate), was θplate = 0°. For the second entry, θplate = 0° and θplate = -13.25° were initially tested with the swept ramp array (discussed in the following section) to determine which orientation produced conditions most favorable for XSWBLI to occur based on the heating signatures observed over the top surface of the model in the IR thermography images. Based on these initial tests, θplate = -13.25° was set for the remainder of the runs in the second entry. For both entries, any model changes were performed in a housing located beneath the closed test section. Prior to performing a run of the tunnel, the housing was sealed and the tunnel started. Once the appropriate freestream conditions were achieved, the model was injected into the test section using a hydraulic injection system. B. Model Geometry For all runs, a 10° half-angle (20° full-angle) wedge model with a sharp leading edge was used. The model is described in detail in Refs. [10,16]. The top surface of the sharp leading edge of the model extended 47.8 mm from its upstream-most edge to a junction with the upstream edge of a stainless steel top plate that then extended an (a) (c) (b) Fig. 1 (a) Schematic of top surface of wedge model with gas seeding insert, (b) perspective view of the model in the 20-Inch Mach 6 tunnel with centerline pressure orifices on sharp leading edge, and (c) a perspective view of the model with stainless steel (top) and SLA middle insert (bottom) during the first entry. Flow occurs from left to right.

Bathel, Brett F.↗

Investigation of the feasibility of optical diagnostic measurements at the exit of the SSME

Under Contract NAS8-36861 sponsored by NASA Marshall Space Flight Center, the United Technologies Research Center is conducting an investigation of the feasibility of remote optical diagnostics to measure temperature, species concentration and velocity at the exit of the Space Shuttle Main Engine (SSME). This is a two phase study consisting of a conceptual design phase followed by a laboratory experimental investigation. The first task of the conceptual design studies is to screen and evaluate the techniques which can be used for the measurements. The second task is to select the most promising technique or techniques, if as expected, more than one type of measurement must be used to measure all the flow variables of interest. The third task is to examine in detail analytically the capabilities and limitations of the selected technique(s). The results of this study are described in the section of this report entitled Conceptual Design Investigations. The conceptual design studies identified spontaneous Raman scattering and photodissociative flow-tagging for measurements respectively of gas temperature and major species concentration and for velocity. These techniques and others that were considered are described in the section describing the conceptual design. The objective of the second phase of investigations was to investigate experimentally the techniques identified in the first phase. The first task of the experimental feasibility study is to design and assemble laboratory scale experimental apparatus to evaluate the best approaches for SSME exit optical diagnostics for temperature, species concentrations and velocity, as selected in the Phase I conceptual design study. The second task is to evaluate performance, investigate limitations, and establish actual diagnostic capabilities, accuracies and precision for the selected optical systems. The third task is to evaluate design requirements and system trade-offs of conceptual instruments. Spontaneous Raman scattering excited by a KrF excimer laser pulse was investigated for SSME exit plane temperature and major species concentration measurements. The relative concentrations of molecular hydrogen and water vapor would be determined by measuring the integrated Q-branch scattering signals through narrow bandpass filters in front of photomultipliers. The temperature would be determined by comparing the signal from a single hydrogen rotational Raman line to the total hydrogen Q-branch signal. The rotational Raman line would be isolated by a monochromator and detected with a PMT.

Shirley, John A.↗

Measurements of Optically Transparent and Mirrored Specimens from the POSA and EOIM III Space Flight Experiments

A selected set of optically transparent specimens and first surface mirror specimens have been examined subsequent to on-orbit exposure. Certain specimens were from the Passive Optical Sample Assembly I and II experiments flown on the MIR Space Station. Other specimens were from the Energetic Oxygen Interaction with materials III experiment flown on the STS in August 1992. A comparison of pre- and post-flight transmission of reflectance measurements, as appropriate, has been carried out. Data from different specimens includes results of measurements for IR, optical, UV and/or vacuum UV wavelength intervals. Results of these measurements clearly show the effects of molecular contamination deposits on the surfaces during the on-orbit exposures. Surface analysis on a attracted set of specimens provides and estimate of contaminant thickness and composition and provides an insight into on-orbit deposition rates and surface oxidation reactions. For both the EOIM III and POSA I & II experiments, the primary source of contamination were outgassed silicones. Both experiments received approximately the same fluence of atomic oxygen (approx. 1-2 x 1020 atoms per square centimeter). ROSA specimens received between approx. 400 and 580 equivalent sun hours (ESH) of solar radiation over an 18 month period in orbit. The EOIM specimens were on an STS flight of about 1 week duration and received only approx. 5-10 ESH of solar radiation.

Pippin, Gary↗

Coincident Observation of Lightning using Spaceborne Spectrophotometer and Ground-Level Electromagnetic Sensors

The present study aims at assessing a possible new way to reveal the properties of lightning flash, using spectrophotometric data obtained by FORMOSAT-2/ISUAL which is the first spaceborne multicolor lightning detector. The ISUAL data was analyzed in conjunction with ground ]based electromagnetic data obtained by Duke magnetic field sensors, NLDN, North Alabama Lightning Mapping Array (LMA), and Kennedy Space Center (KSC) electric field antennas. We first classified the observed events into cloud ]to ]ground (CG) and intra ]cloud (IC) lightning based on the Duke and NLDN measurements and analyzed ISUAL data to clarify their optical characteristics. It was found that the ISUAL optical waveform of CG lightning was strongly correlated with the current moment waveform, suggesting that it is possible to evaluate the electrical properties of lightning from satellite optical measurement to some extent. The ISUAL data also indicated that the color of CG lightning turned to red at the time of return stroke while the color of IC pulses remained unchanged. Furthermore, in one CG event which was simultaneously detected by ISUAL and LMA, the observed optical emissions slowly turned red as the altitude of optical source gradually decreased. All of these results indicate that the color of lightning flash depends on the source altitude and suggest that spaceborne optical measurement could be a new tool to discriminate CG and IC lightning. In the presentation, we will also show results on the comparison between the ISUAL and KSC electric field data to clarify characteristics of each lightning process such as preliminary breakdown, return stroke, and subsequent upward illumination.

Adachi, Toru↗

Electro-optical System Measures Aircraft Deflections

In-flight deflections of aircraft surfaces are measured accurately over wide range of airspeeds and attitudes by electro-optical instrumentation system. Deflections caused by aerodynamic and acceleration forces are measured on wings, stabilizers, helicopter rotors, and other surfaces. Electro-optical system replaces 70-millimeter motor-driven camera previously used to observe deflections.

Fodale, B.↗

Measuring surface displacements optically

Laser system measures changes in position or roughness of surface without physical contact. Using optical correlation technique, displacement of surface is measured by reflection of laser beam and holographic correlation filtering system. System also determines changes in roughness or shape of surface.

Owen, R. B.↗

Spectral line absorption measurement using optical cavities.

A simple technique using a conventional gas laser with spherical mirrors having identical radii of curvature in the nonoscillating regime for spectral line absorption measurements is described and applications for laser work are suggested. The theory of the measurement carried out in the geometrical optical approach for Doppler-broadened lines was checked experimentally and conditions are specified for which measurement inaccuracies of the order of 1% for the peak value of the line absorption coefficient can be obtained. Since the device provides a fine adjustment of the cavity losses, formation of the diffraction modes could be observed in the preoscillating regime of the optical cavity.

Blanaru, D. L.↗