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

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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Nanoscale Subsurface Imaging via Resonant Difference-Frequency Atomic Force Ultrasonic Microscopy

A novel scanning probe microscope methodology has been developed that employs an ultrasonic wave launched from the bottom of a sample while the cantilever of an atomic force microscope, driven at a frequency differing from the ultrasonic frequency by the fundamental resonance frequency of the cantilever, engages the sample top surface. The nonlinear mixing of the oscillating cantilever and the ultrasonic wave in the region defined by the cantilever tip-sample surface interaction force generates difference-frequency oscillations at the cantilever fundamental resonance. The resonance-enhanced difference-frequency signals are used to create images of embedded nanoscale features.

Cantrell, Sean A.↗
NASA NTRS2003

An Ultrasonic Sampler and Sensor Platform for In-Situ Astrobiological Exploration

The search for existing or past life in the Universe is one of the most important objectives of NASA's mission. In support of this objective, ultrasonic based mechanisms are currently being developed at JPL to allow probing and sampling rocks as well as perform as a sensor platform for in-situ astrobiological analysis. The technology is based on the novel Ultrasonic/Sonic Driller/Corer (USDC), which requires low axial force, thereby overcoming one of the major limitations of planetary sampling in low gravity using conventional drills. The USDC was demonstrated to: 1) drill ice and various rocks including granite, diorite, basalt and limestone, 2) not require bit sharpening, and 3) operate at high and low temperatures. The capabilities that are being investigated including probing the ground to select sampling sites, collecting various forms of samples, and hosting sensors for measuring chemical/physical properties. A series of modifications of the USDC basic configuration were implemented leading an ultrasonic abrasion tool (URAT), Ultrasonic Gopher for deep Drilling, and the lab-on-a-drill.

robotics↗
NASA NTRS2010

The Application of Ultrasonic Inspection to Crimped Electrical Connections

The development of a new ultrasonic measurement technique to quantitatively assess wire crimp terminations is discussed. The development of a prototype instrument, based on a modified, commercially available, crimp tool, is demonstrated for applying this technique when wire crimps are installed. The crimp tool has three separate crimping locations that accommodate the three different ferrule diameters. The crimp tool in this study is capable of crimping wire diameters ranging from 12 to 26 American Wire Gauge (AWG). A transducer design is presented that allows for interrogation of each of the three crimp locations on the crimp tool without reconfiguring the device. An analysis methodology, based on transmitted ultrasonic energy and timing of the first received pulse is shown to correlate to both crimp location in the tool and the AWG of the crimp/ferrule combination. The detectability of a number of the crimp failure pathologies, such as missing strands, partially inserted wires and incomplete crimp compression, is discussed. A wave propagation model, solved by finite element analysis, describes the compressional ultrasonic wave propagation through the junction during the crimping process.

Cramer, K. Elliott↗
NASA NTRS2006

Multimode-Guided-Wave Ultrasonic Scanning of Materials

Two documents discuss a method of characterizing advanced composite materials by use of multimode-guided ultrasonic waves. A transmitting transducer excites modulated (e.g., pulsed) ultrasonic waves at one location on a surface of a plate specimen. The waves interact with microstructure and flaws as they propagate through the specimen to a receiving transducer at a different location. The received signal is analyzed to determine the total (multimode) ultrasonic response of the specimen and utilize this response to evaluate microstructure and flaws. The analysis is performed by software that extracts parameters of signals in the time and frequency domains. Scanning is effected by using computer-controlled motorized translation stages to position the transducers at specified pairs of locations and repeating the measurement, data-acquisition, and data-analysis processes at the successive locations. One document presents results of a scan of a specimen containing a delamination.

Roth, Don↗
NASA NTRS2004

Using an Ultrasonic Instrument to Size Extravascular Bubbles

In an ongoing development project, microscopic bubbles in extravascular tissue in a human body will be detected by use of an enhanced version of the apparatus described in Ultrasonic Bubble- Sizing Instrument (MSC-22980), NASA Tech Briefs, Vol. 24, No. 10 (October 2000), page 62. To recapitulate: The physical basis of the instrument is the use of ultrasound to excite and measure the resonant behavior (oscillatory expansion and contraction) of bubbles. The resonant behavior is a function of the bubble diameter; the instrument exploits the diameter dependence of the resonance frequency and the general nonlinearity of the ultrasonic response of bubbles to detect bubbles and potentially measure their diameters. In the cited prior article, the application given most prominent mention was the measurement of gaseous emboli (essentially, gas bubbles in blood vessels) that cause decompression sickness and complications associated with cardiopulmonary surgery. According to the present proposal, the instrument capabilities would be extended to measure extravascular bubbles with diameters in the approximate range of 1 to 30 m. The proposed use of the instrument could contribute further to the understanding and prevention of decompression sickness: There is evidence that suggests that prebreathing oxygen greatly reduces the risk of decompression sickness by reducing the number of microscopic extravascular bubbles. By using the ultrasonic bubble-sizing instrument to detect and/or measure the sizes of such bubbles, it might be possible to predict the risk of decompression sickness. The instrument also has potential as a tool to guide the oxygen-prebreathing schedules of astronauts; high-altitude aviators; individuals who undertake high-altitude, low-opening (HALO) parachute jumps; and others at risk of decompression sickness. For example, an individual at serious risk of decompression sickness because of high concentrations of extravascular microscopic bubbles could be given a warning to continue to prebreathe oxygen until it was safe to decompress.

Magari, Patrick J.↗
NASA NTRS2003

Folded Resonant Horns for Power Ultrasonic Applications

Folded horns have been conceived as alternatives to straight horns used as resonators and strain amplifiers in power ultrasonic systems. Such systems are used for cleaning, welding, soldering, cutting, and drilling in a variety of industries. In addition, several previous NASA Tech Briefs articles have described instrumented drilling, coring, and burrowing machines that utilize combinations of sonic and ultrasonic vibrational actuation. The main advantage of a folded horn, relative to a straight horn of the same resonance frequency, is that the folded horn can be made shorter (that is, its greatest linear dimension measured from the outside can be made smaller). Alternatively, for a given length, the resonance frequency can be reduced. Hence, the folded-horn concept affords an additional degree of design freedom for reducing the length of an ultrasonic power system that includes a horn.

Sherrit, Stewart↗
NASA NTRS2013

Ultrasonic Detectors Safely Identify Dangerous, Costly Leaks

In 1990, NASA grounded its space shuttle fleet. The reason: leaks detected in the hydrogen fuel systems of the Space Shuttles Atlantis and Columbia. Unless the sources of the leaks could be identified and fixed, the shuttles would not be safe to fly. To help locate the existing leaks and check for others, Kennedy Space Center engineers used portable ultrasonic detectors to scan the fuel systems. As a gas or liquid escapes from a leak, the resulting turbulence creates ultrasonic noise, explains Gary Mohr, president of Elmsford, New York-based UE Systems Inc., a long-time leader in ultrasonic detector technologies. "In lay terms, the leak is like a dog whistle, and the detector is like the dog ear." Because the ultrasound emissions from a leak are highly localized, they can be used not only to identify the presence of a leak but also to help pinpoint a leak s location. The NASA engineers employed UE s detectors to examine the shuttle fuel tanks and solid rocket boosters, but encountered difficulty with the devices limited range-certain areas of the shuttle proved difficult or unsafe to scan up close. To remedy the problem, the engineers created a long-range attachment for the detectors, similar to "a zoom lens on a camera," Mohr says. "If you are on the ground, and the leak is 50 feet away, the detector would now give you the same impression as if you were only 25 feet away." The enhancement also had the effect of reducing background noise, allowing for a clearer, more precise detection of a leak s location.

Source record↗
NASA NTRS2013

Pulsed ultrasonic stir welding system

An ultrasonic stir welding system includes a welding head assembly having a plate and a rod passing through the plate. The rod is rotatable about a longitudinal axis thereof. During a welding operation, ultrasonic pulses are applied to the rod as it rotates about its longitudinal axis. The ultrasonic pulses are applied in such a way that they propagate parallel to the longitudinal axis of the rod.

Ding, R. Jeffrey↗
NASA NTRS2013

Pulsed ultrasonic stir welding method

A method of performing ultrasonic stir welding uses a welding head assembly to include a plate and a rod passing through the plate. The rod is rotatable about a longitudinal axis thereof. In the method, the rod is rotated about its longitudinal axis during a welding operation. During the welding operation, a series of on-off ultrasonic pulses are applied to the rod such that they propagate parallel to the rod's longitudinal axis. At least a pulse rate associated with the on-off ultrasonic pulses is controlled.

Ding, R. Jeffrey↗
NASA NTRS2014

Ultrasonic Inspection to Quantify Failure Pathologies of Crimped Electrical Connections

Previous work has shown that ultrasonic inspection provides a means of assessing electrical crimp quality that ensures the electrical and mechanical integrity of an initial crimp before the installation process is completed. The amplitude change of a compressional ultrasonic wave propagating at right angles to the wire axis and through the junction of a crimp termination was shown to correlate with the results of destructive pull tests, which is a standard for assessing crimp wire junction quality. Of additional concern are crimps made at high speed assembly lines for wiring harnesses, which are used for critical applications, such as in aircraft. During high-speed assembly it is possible that many faulty crimps go undetected until long after assembly, and fail in service. The position and speed of the crimping jaw become factors as the high-speed crimp is formed. The work presented in this paper is designed to cover the more difficult and more subtle area of high-speed crimps by taking into account the rate change of the measurements. Building on the previous work, we present an analysis methodology, based on transmitted ultrasonic energy and timing of the first received pulse that is shown to correlate to the gauge of the crimp/ferrule combination and the position of the crimping jaw. Results demonstrating the detectability of a number of the crimp failure pathologies, such as missing strands, partially inserted wires and incomplete crimp compression, are presented. The ability of this technique to estimate crimp height, a mechanical measure of crimp quality, is discussed.

Cramer, K. Elliott↗
NASA NTRS2014

Ultrasonic Method for Deployment Mechanism Bolt Element Preload Verification

Deployment mechanisms play a pivotal role in mission success. These mechanisms often incorporate bolt elements for which a preload within a specified range is essential for proper operation. A common practice is to torque these bolt elements to a specified value during installation. The resulting preload, however, can vary significantly with applied torque for a number of reasons. The goal of this effort was to investigate ultrasonic methods as an alternative for bolt preload verification in such deployment mechanisms. A family of non-explosive release mechanisms widely used by satellite manufacturers was chosen for the work. A willing contractor permitted measurements on a sampling of bolt elements for these release mechanisms that were installed by a technician following a standard practice. A variation of approximately 50% (+/- 25%) in the resultant preloads was observed. An alternative ultrasonic method to set the preloads was then developed and calibration data was accumulated. The method was demonstrated on bolt elements installed in a fixture instrumented with a calibrated load cell and designed to mimic production practice. The ultrasonic method yielded results within +/- 3% of the load cell reading. The contractor has since adopted the alternative method for its future production. Introduction

Johnson, Eric C.↗
NASA NTRS2015

Ultrasonic Stir Welding

NASA Marshall Space Flight Center (MSFC) developed Ultrasonic Stir Welding (USW) to join large pieces of very high-strength metals such as titanium and Inconel. USW, a solid-state weld process, improves current thermal stir welding processes by adding high-power ultrasonic (HPU) energy at 20 kHz frequency. The addition of ultrasonic energy significantly reduces axial, frictional, and shear forces; increases travel rates; and reduces wear on the stir rod, which results in extended stir rod life. The USW process decouples the heating, stirring, and forging elements found in the friction stir welding process allowing for independent control of each process element and, ultimately, greater process control and repeatability. Because of the independent control of USW process elements, closed-loop temperature control can be integrated into the system so that a constant weld nugget temperature can be maintained during welding.

Nabors, Sammy↗
NASA NTRS2015

Ultrasonic Stir Welding Development for Ground-Based and In Situ Fabrication and Repair for In-Space Propulsion Systems/Commercial Space Sector

The completed Center Innovation Fund (CIF) project used the upgraded Ultrasonic Stir Weld (USW) Prototype System (built in 2013/2014) to begin characterizing the weld process using 2219 aluminum (fig. 1). This work is being done in Bldg. 4755 at NASA Marshall Space Flight Center (MSFC). The capabilities of the USW system provides the means to precisely control and document individual welding parameters. The current upgraded system has the following capabilities: (1) Ability to 'pulse' ultrasonic (US) energy on and off and adjust parameters real-time (travel speed, spindle rpm, US amplitude, X and Z axis positions, and plunge and pin axis force; (2) Means to measure draw force; (3) Ability to record US power versus time; (4) Increasing stiffness of Z axis drive and reduce head deflection using laser technology; (5) Adding linear encoder to better control tool penetration setting; (6) Ultrasonic energy integrated into stir rod and containment plate; (7) Maximum 600 rpm; (8) Maximum Z force 15,000 lb; (9) Real-time data acquisition and logging capabilities at a minimum frequency of 10 Hz; and (10) Two separate transducer power supplies operating at 4.5 kW power.

Ding, Jeff↗
NASA NTRS2016

Ultrasonic NDE Simulation for Composite Manufacturing Defects

The increased use of composites in aerospace components is expected to continue into the future. The large scale use of composites in aerospace necessitates the development of composite-appropriate nondestructive evaluation (NDE) methods to quantitatively characterize defects in as-manufactured parts and damage incurred during or post manufacturing. Ultrasonic techniques are one of the most common approaches for defect/damage detection in composite materials. One key technical challenge area included in NASA's Advanced Composite's Project is to develop optimized rapid inspection methods for composite materials. Common manufacturing defects in carbon fiber reinforced polymer (CFRP) composites include fiber waviness (in-plane and out-of-plane), porosity, and disbonds; among others. This paper is an overview of ongoing work to develop ultrasonic wavefield based methods for characterizing manufacturing waviness defects. The paper describes the development and implementation of a custom ultrasound simulation tool that is used to model ultrasonic wave interaction with in-plane fiber waviness (also known as marcelling). Wavefield data processing methods are applied to the simulation data to explore possible routes for quantitative defect characterization.

Leckey, Cara A. C.↗
NASA NTRS2018

Method to Control Crimping Processes Using Ultrasonic Transmission Analysis

A method of crimping wires includes positioning a wire/terminal combination between first and second crimp forming tools. A force is applied to the crimp forming tools to deform the wire/terminal combination. The method further includes measuring ultrasonic energy that is transmitted across the wire/terminal combination as the terminal is being deformed. A rate of change of the magnitude of the ultrasonic energy is also determined as the terminal is being deformed. The crimping process is terminated if the rate of change of the magnitude of the ultrasonic energy falls below a predefined threshold level. Data gathered during the crimping process can also be utilized to determine if a faulty crimp has occurred.

Cramer, Karl Elliott↗
NASA NTRS2019

Ultrasonic Gear Steel Fatigue at NASA

Gear tooth bending fatigue life is one of the main drivers of rotorcraft gear box weight and maintenance cost. Depending on rotorcraft gearbox speed, 10,000 flight hours can easily mean reaching gear tooth bending fatigue cycles in the 10^10 cycle regime. Traditionally gear fatigue life in the 10^10 cycle regime is estimated based on empirical correction factors applied to the traditional fatigue limit of 10^7 cycles. In order to improve on this method of life prediction, enable better gear box design, and reduce gear box maintenance cost, NASA has started an ultrasonic gear steel fatigue program to quantify the 10^10 life of gear steels. Ultrasonic fatigue testing makes use of piezo electric actuators and resonance to generate stress-strain cycles at 20 kHz. The ability to test gear steals at 20 kHz reduces test time for 10^10 cycles from roughly 16 years with traditional 20 Hz testing to 6 days. In this presentation, the establishment of NASA's ultrasonic test capability, results to date, and future testing plans will be discussed.

Tallerico, Thomas F.↗
NASA NTRSDate not supplied

Evaluation Marcelling in Composites using Ultrasonic Guided Wave

Thermoplastic composite (TPC) material seldom manifests in-plane fiber waviness during manufacturing. In-plane fiber waviness is called marcelling. Marcelling com-promises the composite strength and performance. When present in a structure, marcelling is not only a surface defect but can extend partially along the thickness of the composite. There is no established nondestructive evaluation (NDE) method to detect and quantify marcelling in composite. Ultrasonic guided waves can saturate the complete thickness of a composite structure. Thus, physics of guided wave creates an opportunity to detect and quantify the marcelling in composites. Before guided waves could be used to detect marcelling, it is necessary to quantify the marcelling in the structure and identify the marcelling affected zones (MAZE). In this research first, high frequency scanning acoustic microscopy (SAM) was performed to quantify the marcelling and statistical distribution of the defects at different MAZE was obtained. Next the MAZE with known statistical distribution of quantified marcelling (marcelling wavelength and marcelling amplitude) was inspected using ultrasonic guided wave setup. The method quantified the guided wave feature as a function of quantitative degree of marcelling. The overarching objective of this research is to implement post process NDE inspection of TPC large structures where in plane fiber waviness or marcelling can be detected and MAZEs could be identified. Primary fining is that the reduction of wave velocity and amplitude of ultrasonic guided wave could be good indicators of MAZE. However, more rigorous calibration is necessary where inspection direction is carefully devised with respect to the marcelling.

HiCAM↗