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At least 253 records · Page 14

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NASA NTRS1997

Ultrasonic Studies of Composites Undergoing Thermal and Fatigue Loading

New composite materials possess attractive properties for use in advanced aircraft. A necessary requirement for their introduction into aeronautic use is an accurate understanding of their long term aging processes so that proper design criteria can be established. In order to understand those properties, these composites must be exposed to thermal and load cycles that are characteristic of flight conditions. Additionally, airline companies will require nondestructive evaluation (NDE) methods that can be used in the field to assess the condition of these new materials as they age. As part of an effort to obtain the required information about new composites for aviation use, we are performing ultrasonic measurements both in the NDE laboratory and in the materials testing laboratory at NASA. The materials testing laboratory is equipped with environmental chambers mounted on load frames so that composite samples can be exposed to thermal and loading cycles representative of flight protocols. Applying both temperature and load simultaneously will help to highlight temperature and load interactions during the aging of these composite materials. This study reports on our initial ultrasonic attenuation results from thermoset and thermoplastic composite samples. Ultrasonic attenuation measurements have been used reliably to assess the effects of material degradation. For example, recently, researchers have shown that by using frequencies of ultrasound on the order of 24 MHz, they could obtain adequate contrast in the evaluation of thermal degradation in these composites. This paper will present data that shows results at a lower frequency range. In addition, we report results on the frequency dependence of attenuation as the slope of attenuation with respect to frequency, beta = delta alpha (f) / delta f. The slope of attenuation is an attractive parameter since it is quantitative, yet does not require interface corrections like conventional quantitative attenuation measurements. This is a consequence of the assumption that interface correction terms are frequently independent. Uncertainty in those corrections terms compromises the value of conventional quantitative attenuation data.

Madaras, Eric I.↗

NASA NTRS1998

Single-Transducer, Ultrasonic Imaging Method for High-Temperature Structural Materials Eliminates the Effect of Thickness Variation in the Image

NASA Lewis Research Center's Life Prediction Branch, in partnership with Sonix, Inc., and Cleveland State University, recently advanced the development of, refined, and commercialized an advanced nondestructive evaluation (NDE) inspection method entitled the Single Transducer Thickness-Independent Ultrasonic Imaging Method. Selected by R&D Magazine as one of the 100 most technologically significant new products of 1996, the method uses a single transducer to eliminate the superimposing effects of thickness variation in the ultrasonic images of materials. As a result, any variation seen in the image is due solely to microstructural variation. This nondestructive method precisely and accurately characterizes material gradients (pore fraction, density, or chemical) that affect the uniformity of a material's physical performance (mechanical, thermal, or electrical). Advantages of the method over conventional ultrasonic imaging include (1) elimination of machining costs (for precision thickness control) during the quality control stages of material processing and development and (2) elimination of labor costs and subjectivity involved in further image processing and image interpretation. At NASA Lewis, the method has been used primarily for accurate inspections of high temperature structural materials including monolithic ceramics, metal matrix composites, and polymer matrix composites. Data were published this year for platelike samples, and current research is focusing on applying the method to tubular components. The initial publicity regarding the development of the method generated 150 requests for further information from a wide variety of institutions and individuals including the Federal Bureau of Investigation (FBI), Lockheed Martin Corporation, Rockwell International, Hewlett Packard Company, and Procter & Gamble Company. In addition, NASA has been solicited by the 3M Company and Allison Abrasives to use this method to inspect composite materials that are manufactured by these companies.

Roth, Don J.↗

NASA NTRS2004

Sandwich Panels Evaluated With Ultrasonic Spectroscopy

Enhanced, lightweight material systems, such as 17-4PH stainless steel sandwich panels are being developed for use as fan blades and fan containment systems for next-generation engines. The bond strength between the core and face sheets is critical in maintaining the structural integrity of the sandwich structure. To improve the inspection and production of these systems, researchers at the NASA Glenn Research Center are using nondestructive evaluation (NDE) techniques, such as ultrasonic spectroscopy, to evaluate the brazing quality between the face plates and the metallic foam core. The capabilities and limitations of a swept-frequency approach to ultrasonic spectroscopy were evaluated with respect to these sandwich structures. This report discusses results from three regions of a sandwich panel representing different levels of brazing quality between the outer face plates and a metallic foam core. Each region was investigated with ultrasonic spectroscopy. Then, on the basis of the NDE results, three shear specimens sectioned from the sandwich panel to contain each of these regions were mechanically tested.

Cosgriff, Laura M.↗

NASA NTRS2003

Delaminations Investigated With Ultrasonic Spectroscopy

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

Cosgriff, Laura M.↗

NASA NTRS1998

Method and apparatus for dual amplitude dual time-of-flight ultrasonic imaging

A method and apparatus for ultrasonic imaging which includes scanning a test specimen located in a test fixture in a predetermined scan pattern. Propagating and receiving reflected pulses of ultrasonic energy from an ultrasonic transducer directed to a surface of the test specimen. Detecting and generating data of both the amplitude and the depth of a defect in the test specimen from the pulses received from the test specimen. Merging the data of the amplitude and the data of the depth of the defect into composite data and then displaying the composite data in a three dimensional image whereby a mesh of both amplitude and depth data of the defect is displayed in a single image of the defect.

Chern, Engmin James↗

NASA NTRS2002

Detection of cystic structures using pulsed ultrasonically induced resonant cavitation

Apparatus and method for early detection of cystic structures indicative of ovarian and breast cancers uses ultrasonic wave energy at a unique resonance frequency for inducing cavitation in cystic fluid characteristic of cystic structures in the ovaries associated with ovarian cancer, and in cystic structures in the breast associated with breast cancer. Induced cavitation bubbles in the cystic fluid implode, creating implosion waves which are detected by ultrasonic receiving transducers attached to the abdomen of the patient. Triangulation of the ultrasonic receiving transducers enables the received signals to be processed and analyzed to identify the location and structure of the cyst.

Bar-Cohen, Yoseph↗

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↗