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Nondestructive Evaluation for the Space Shuttle's Wing Leading Edge

The loss of the Space Shuttle Columbia highlighted concerns about the integrity of the Shuttle's thermal protection system, which includes Reinforced Carbon-Carbon (RCC) on the leading edge. This led NASA to investigate nondestructive evaluation (NDE) methods for certifying the integrity of the Shuttle's wing leading edge. That investigation was performed simultaneously with a large study conducted to understand the impact damage caused by errant debris. Among the many advanced NDE methods investigated for applicability to the RCC material, advanced digital radiography, high resolution computed tomography, thermography, ultrasound, acoustic emission and eddy current systems have demonstrated the maturity and success for application to the Shuttle RCC panels. For the purposes of evaluating the RCC panels while they are installed on the orbiters, thermographic detection incorporating principal component analysis (PCA) and eddy current array scanning systems demonstrated the ability to measure the RCC panels from one side only and to detect several flaw types of concern. These systems were field tested at Kennedy Space Center (KSC) and at several locations where impact testing was being conducted. Another advanced method that NASA has been investigating is an automated acoustic based detection system. Such a system would be based in part on methods developed over the years for acoustic emission testing. Impact sensing has been demonstrated through numerous impact tests on both reinforced carbon-carbon (RCC) leading edge materials as well as Shuttle tile materials on representative aluminum wing structures. A variety of impact materials and conditions have been evaluated including foam, ice, and ablator materials at ascent velocities as well as simulated hypervelocity micrometeoroid and orbital debris impacts. These tests have successfully demonstrated the capability to detect and localize impact events on Shuttle's wing structures. A first generation impact sensing system has been designed for the next Shuttle flight and is undergoing final evaluation for deployment on the Shuttle's first return to flight. This system will employ wireless accelerometer sensors that were qualified for other applications on previous Shuttle flights. These sensors will be deployed on the wing's leading edge to detect impacts on the RCC leading edge panels. The application of these methods will help to insure the continued integrity of the Shuttle wing's leading edge system as the Shuttle flights resume and until their retirement.

Eric I Madaras↗

NASA NTRS2005

Infrared On-Orbit Inspection of Shuttle Orbiter Reinforced Carbon-Carbon Using Solar Heating

Thermographic nondestructive inspection techniques have been shown to provide quantitative, large area damage detection capabilities for the ground inspection of the reinforced carbon-carbon (RCC) used for the wing leading edge of the Shuttle orbiter. The method is non-contacting and able to inspect large areas in a relatively short inspection time. Thermal nondestructive evaluation (NDE) inspections have been shown to be applicable for several applications to the Shuttle in preparation for return to flight, including for inspection of RCC panels during impact testing, and for between-flight orbiter inspections. The focus of this work is to expand the capabilities of the thermal NDE methodology to enable inspection by an astronaut during orbital conditions. The significant limitations of available resources, such as weight and power, and the impact of these limitations on the inspection technique are discussed, as well as the resultant impact on data analysis and processing algorithms. Of particular interest is the impact to the inspection technique resulting from the use of solar energy as a heat source, the effect on the measurements due to working in the vacuum of space, and the effect of changes in boundary conditions, such as radiation losses seen by the material, on the response of the RCC. The resultant effects on detectability limits are discussed. Keywords: Nondestructive Evaluation, Shuttle, on-orbit inspection, thermography, infrared

Howell, P. A.↗

NASA NTRS2006

Pressure Gradient Effects on Hypersonic Cavity Flow Heating

The effect of a pressure gradient on the local heating disturbance of rectangular cavities tested at hypersonic freestream conditions has been globally assessed using the two-color phosphor thermography method. These experiments were conducted in the Langley 31-Inch Mach 10 Tunnel and were initiated in support of the Space Shuttle Return-To-Flight Program. Two blunted-nose test surface geometries were developed, including an expansion plate test surface with nearly constant negative pressure gradient and a flat plate surface with nearly zero pressure gradient. The test surface designs and flow characterizations were performed using two-dimensional laminar computational methods, while the experimental boundary layer state conditions were inferred using the measured heating distributions. Three-dimensional computational predictions of the entire model geometry were used as a check on the design process. Both open-flow and closed-flow cavities were tested on each test surface. The cavity design parameters and the test condition matrix were established using the computational predictions. Preliminary conclusions based on an analysis of only the cavity centerline data indicate that the presence of the pressure gradient did not alter the open cavity heating for laminar-entry/laminar-exit flows, but did raise the average floor heating for closed cavities. The results of these risk-reduction studies will be used to formulate a heating assessment of potential damage scenarios occurring during future Space Shuttle flights.

Everhart, Joel L.↗

NASA NTRS2006

Signal to Noise Studies on Thermographic Data with Fabricated Defects for Defense Structures

There is a growing international interest in thermal inspection systems for asset life assessment and management of defense platforms. The efficacy of flash thermography is generally enhanced by applying image processing algorithms to the observations of raw temperature. Improving the defect signal to noise ratio (SNR) is of primary interest to reduce false calls and allow for easier interpretation of a thermal inspection image. Several factors affecting defect SNR were studied such as data compression and reconstruction using principal component analysis and time window processing.

Zalameda, Joseph N.↗

NASA NTRS2006

Development of an Extra-vehicular (EVA) Infrared (IR) Camera Inspection System

Designed to fulfill a critical inspection need for the Space Shuttle Program, the EVA IR Camera System can detect crack and subsurface defects in the Reinforced Carbon-Carbon (RCC) sections of the Space Shuttle s Thermal Protection System (TPS). The EVA IR Camera performs this detection by taking advantage of the natural thermal gradients induced in the RCC by solar flux and thermal emission from the Earth. This instrument is a compact, low-mass, low-power solution (1.2cm3, 1.5kg, 5.0W) for TPS inspection that exceeds existing requirements for feature detection. Taking advantage of ground-based IR thermography techniques, the EVA IR Camera System provides the Space Shuttle program with a solution that can be accommodated by the existing inspection system. The EVA IR Camera System augments the visible and laser inspection systems and finds cracks and subsurface damage that is not measurable by the other sensors, and thus fills a critical gap in the Space Shuttle s inspection needs. This paper discusses the on-orbit RCC inspection measurement concept and requirements, and then presents a detailed description of the EVA IR Camera System design.

Gazarik, Michael↗

NASA NTRS2006

Shuttle Return To Flight Experimental Results: Protuberance Effects on Boundary Layer Transition

The effect of isolated roughness elements on the windward boundary layer of the Shuttle Orbiter has been experimentally examined in the Langley Aerothermodynamic Laboratory in support of an agency-wide effort to prepare the Shuttle Orbiter for return to flight. This experimental effort was initiated to provide a roughness effects database for developing transition criteria to support on-orbit decisions to repair damage to the thermal protection system. Boundary layer transition results were obtained using trips of varying heights and locations along the centerline and attachment lines of 0.0075-scale models. Global heat transfer images using phosphor thermography of the Orbiter windward surface and the corresponding heating distributions were used to infer the state of the boundary layer (laminar, transitional, or turbulent). The database contained within this report will be used to formulate protuberance-induced transition correlations using predicted boundary layer edge parameters.

Liechty, Derek S.↗

NASA NTRS2006

Shuttle Damage/Repair from the Perspective of Hypersonic Boundary Layer Transition - Experimental Results

An overview is provided of the experimental wind tunnel program conducted at the NASA Langley Research Center Aerothermodynamics Laboratory in support of an agency-wide effort to prepare the Shuttle Orbiter for Return-to-Flight. The effect of an isolated protuberance and an isolated rectangular cavity on hypersonic boundary layer transition onset on the windward surface of the Shuttle Orbiter has been experimentally characterized. These experimental studies were initiated to provide a protuberance and cavity effects database for developing hypersonic transition criteria to support on-orbit disposition of thermal protection system damage or repair. In addition, a synergistic experimental investigation was undertaken to assess the impact of an isolated mass-flow entrainment source (simulating pyrolysis/outgassing from a proposed tile repair material) on boundary layer transition. A brief review of the relevant literature regarding hypersonic boundary layer transition induced from cavities and localized mass addition from ablation is presented. Boundary layer transition results were obtained using 0.0075-scale Orbiter models with simulated tile damage (rectangular cavities) of varying length, width, and depth and simulated tile damage or repair (protuberances) of varying height. Cavity and mass addition effects were assessed at a fixed location (x/L = 0.3) along the model centerline in a region of near zero pressure gradient. Cavity length-to-depth ratio was systematically varied from 2.5 to 17.7 and length-to-width ratio of 1 to 8.5. Cavity depth-to-local boundary layer thickness ranged from 0.5 to 4.8. Protuberances were located at several sites along the centerline and port/starboard attachment lines along the chine and wing leading edge. Protuberance height-to-boundary layer thickness was varied from approximately 0.2 to 1.1. Global heat transfer images and heating distributions of the Orbiter windward surface using phosphor thermography were used to infer the state of the boundary layer (laminar, transitional, or turbulent). Test parametrics include angles-of-attack of 30 deg and 40 deg, sideslip angle of 0 deg, freestream Reynolds numbers from 0.02x106 to 7.3x106 per foot, edge-to-wall temperature ratio from 0.4 to 0.8, and normal shock density ratios of approximately 5.3, 6.0, and 12 in Mach 6 air, Mach 10 air, and Mach 6 CF4, respectively. Testing to simulate the effects of ablation from a proposed tile repair concept indicated that transition was not a concern. The experimental protuberance and cavity databases highlighted in this report were used to formulate boundary layer transition correlations that were an integral part of an analytical process to disposition observed Orbiter TPS damage during STS- 114.

Horvath, Thomas J.↗

NASA NTRS1995

Nondestructive Determination of Heat/Fire Damage to Polymer- Matrix Composites Using Obliquely Insonified Ultrasonic Waves

Heat and fire damage to composite structures cause loss of strength that cannot be detected by current NDE methods unless physical damage occurs. Further, there is a lack of fundamental understanding of the mechanism of damage from thermal exposure of organic matrix composites to elevated temperatures. Information compiled from field reports and lab experiments increasingly suggests that there is material degradation and it is not necessarily involved with the introduction of physical defects. In recent years, various researchers examined the potential to identifying thermal degradation to organic matrix composites prior to delamination. The methods that were used include: ultrasonics, backscattered X-ray, eddy current, thermography, drift and LPF spectroscopies, acousto-ultrasonics and hardness testing. None of these methods were able to correlate NDE results with loss of mechanical properties.

polymer-matrix composite fire damage NDE nondestru↗

NASA NTRS2003

Capturing a failure of an ASIC in-situ, using infrared radiometry and image processing software

Failures in electronic devices can sometimes be tricky to locate-especially if they are buried inside radiation-shielded containers designed to work in outer space. Such was the case with a malfunctioning ASIC (Application Specific Integrated Circuit) that was drawing excessive power at a specific temperature during temperature cycle testing. To analyze the failure, infrared radiometry (thermography) was used in combination with image processing software to locate precisely where the power was being dissipated at the moment the failure took place. The IR imaging software was used to make the image of the target and background, appear as unity. As testing proceeded and the failure mode was reached, temperature changes revealed the precise location of the fault. The results gave the design engineers the information they needed to fix the problem. This paper describes the techniques and equipment used to accomplish this failure analysis.

infrared↗

NASA NTRS2007

Testing of the Crew Exploration Vehicle in NASA Langley's Unitary Plan Wind Tunnel

As part of a strategic, multi-facility test program, subscale testing of NASA s Crew Exploration Vehicle was conducted in both legs of NASA Langley s Unitary Plan Wind Tunnel. The objectives of these tests were to generate aerodynamic and surface pressure data over a range of supersonic Mach numbers and reentry angles of attack for experimental and computational validation and aerodynamic database development. To provide initial information on boundary layer transition at supersonic test conditions, transition studies were conducted using temperature sensitive paint and infrared thermography optical techniques. To support implementation of these optical diagnostics in the Unitary Wind Tunnel, the experiment was first modeled using the Virtual Diagnostics Interface software. For reentry orientations of 140 to 170 degrees (heat shield forward), windward surface flow was entirely laminar for freestream unit Reynolds numbers equal to or less than 3 million per foot. Optical techniques showed qualitative evidence of forced transition on the windward heat shield with application of both distributed grit and discreet trip dots. Longitudinal static force and moment data showed the largest differences with Mach number and angle of attack variations. Differences associated with Reynolds number variation and/or laminar versus turbulent flow on the heat shield were very small. Static surface pressure data supported the aforementioned trends with Mach number, Reynolds number, and angle of attack.

Murphy, Kelly J.↗

NASA NTRS2007

Testing of Full Scale Flight Qualified Kevlar Composite Overwrapped Pressure Vessels

Many decades ago NASA identified a need for low-mass pressure vessels for carrying various fluids aboard rockets, spacecraft, and satellites. A pressure vessel design known as the composite overwrapped pressure vessel (COPV) was identified to provide a weight savings over traditional single-material pressure vessels typically made of metal and this technology has been in use for space flight applications since the 1970's. A typical vessel design consisted of a thin liner material, typically a metal, overwrapped with a continuous fiber yarn impregnated with epoxy. Most designs were such that the overwrapped fiber would carry a majority of load at normal operating pressures. The weight advantage for a COPV versus a traditional singlematerial pressure vessel contributed to widespread use of COPVs by NASA, the military, and industry. This technology is currently used for personal breathing supply storage, fuel storage for auto and mass transport vehicles and for various space flight and aircraft applications. The NASA Engineering and Safety Center (NESC) was recently asked to review the operation of Kevlar 2 and carbon COPVs to ensure they are safely operated on NASA space flight vehicles. A request was made to evaluate the life remaining on the Kevlar COPVs used on the Space Shuttle for helium and nitrogen storage. This paper provides a review of Kevlar COPV testing relevant to the NESC assessment. Also discussed are some key findings, observations, and recommendations that may be applicable to the COPV user community. Questions raised during the investigations have revealed the need for testing to better understand the stress rupture life and age life of COPVs. The focus of this paper is to describe burst testing of Kevlar COPVs that has been completed as a part of an the effort to evaluate the effects of ageing and shelf life on full scale COPVs. The test articles evaluated in this discussion had a diameter of 22 inches for S/N 014 and 40 inches for S/N 011. The time between manufacture and burst was 28 and 22 years. Visual inspection, shearography, heat soak thermography and borescope inspection were performed on vessel S/N 011 and all but shearography was performed on S/N 014 before they were tested and details of this work can be found in a companion paper titled, "Nondestructive Methods and Special Test Instrumentation Supporting NASA Composite Overwrapped Pressure Vessel Assessments." The vessels were instrumented so that measurements could be made to aid in the understanding of vessel response. Measurements made on the test articles included girth, boss displacement, internal volume, multiple point strain, full field strain, eddy current, acoustic emission (AE) pressure and temperature. The test article before and during burst is shown with the pattern used for digital image correlation full field strain measurement blurring as the vessel fails.

Greene, Nathanael↗

NASA NTRS1977

Liquid-Cooled Garment

A liquid-cooled bra, offshoot of Apollo moon suit technology, aids the cancer-detection technique known as infrared thermography. Water flowing through tubes in the bra cools the skin surface to improve resolution of thermograph image.

Source record↗

NASA NTRS2007

Overview of Experimental Capabilities - Supersonics

This viewgraph presentation gives an overview of experimental capabilities applicable to the area of supersonic research. The contents include: 1) EC Objectives; 2) SUP.11: Elements; 3) NRA; 4) Advanced Flight Simulator Flexible Aircraft Simulation Studies; 5) Advanced Flight Simulator Flying Qualities Guideline Development for Flexible Supersonic Transport Aircraft; 6) Advanced Flight Simulator Rigid/Flex Flight Control; 7) Advanced Flight Simulator Rapid Sim Model Exchange; 8) Flight Test Capabilities Advanced In-Flight Infrared (IR) Thermography; 9) Flight Test Capabilities In-Flight Schlieren; 10) Flight Test Capabilities CLIP Flow Calibration; 11) Flight Test Capabilities PFTF Flowfield Survey; 12) Ground Test Capabilities Laser-Induced Thermal Acoustics (LITA); 13) Ground Test Capabilities Doppler Global Velocimetry (DGV); 14) Ground Test Capabilities Doppler Global Velocimetry (DGV); and 15) Ground Test Capabilities EDL Optical Measurement Capability (PIV) for Rigid/Flexible Decelerator Models.

Banks, Daniel W.↗

NASA NTRS2007

Fabrication and Characterization of Diffusion Bonds for Silicon Carbide

Diffusion bonds of silicon carbide (SiC) were fabricated using several different types of titanium (Ti) based interlayers between the SiC substrates. The interlayers were an alloyed Ti foil, a pure Ti foil, and a physically vapor deposited (PVD) Ti coating. Microscopy was conducted to evaluate the cross-sections of the resulting bonds. Microprobe analysis identified reaction formed phases in the diffusion bonded region. Uniform and well adhered bonds were formed between the SiC substrates. In the case where the alloyed Ti foil or a thick Ti coating (i.e. 20 micron) was used as the interlayer, microcracks and several phases were present in the diffusion bonds. When a thinner interlayer was used (i.e. 10 micron PVD Ti), no microcracks were observed and only two reaction formed phases were present. The two phases were preferred and fully reacted phases that did not introduce thermal stresses or microcracks during the cool-down stage after processing. Diffusion bonded samples were evaluated with the non-destructive evaluation (NDE) methods of pulsed thermography and immersion ultrasonic testing. Joined SiC substrates that were fully bonded and that had simulated bond flaws in the interlayer were also evaluated using immersion ultrasound. Pull testing was conducted on the bonds to determine the tensile strength. To demonstrate the joining approach for a complex multilayered component for a low NOx injector application, the diffusion bonding approach was used to join three 4" diameter SiC discs that contained complex fuel and air flow channels.

Halbig, Michael↗

NASA NTRS2008

Aerothermodynamic Testing and Boundary Layer Trip Sizing of the HIFiRE Flight 1 Vehicle

An experimental wind tunnel test was conducted in the NASA Langley Research Center s 20-Inch Mach 6 Air Tunnel in support of the Hypersonic International Flight Research Experimentation Program. The information in this report is focused on the Flight 1 configuration, the first in a series of flight experiments. This report documents experimental measurements made over a range of Reynolds numbers and angles of attack on several scaled ceramic heat transfer models of the Flight 1 payload. Global heat transfer was measured using phosphor thermography and the resulting images and heat transfer distributions were used to infer the state of the boundary layer on the vehicle windside and leeside surfaces. Boundary layer trips were used to force the boundary layer turbulent, and a brief study was conducted to determine the effectiveness of the trips with various heights. The experimental data highlighted in this test report were used to size and place the boundary layer trip for the flight test vehicle.

Berger, Karen T.↗

NASA NTRS2008

Aerothermodynamic Testing of Protuberances and Penetrations on the NASA Crew Exploration Vehicle Heat Shield in the NASA Langley 20-Inch Mach 6 Air Tunnel

An experimental wind tunnel program is being conducted in support of an Agency wide effort to develop a replacement for the Space Shuttle and to support the NASA s long-term objective of returning to the moon and then on to Mars. This paper documents experimental measurements made on several scaled ceramic heat transfer models of the proposed Crew Exploration Vehicle. Global heat transfer images and heat transfer distributions obtained using phosphor thermography were used to infer interference heating on the Crew Exploration Vehicle Cycle 1 heat shield from local protuberances and penetrations for both laminar and turbulent heating conditions. Test parametrics included free stream Reynolds numbers of 1.0x10(exp 6)/ft to 7.25x10(exp 6)/ft in Mach 6 air at a fixed angle-of-attack. Single arrays of discrete boundary layer trips were used to trip the boundary layer approaching the protuberances/penetrations to a turbulent state. Also, the effects of three compression pad diameters, two radial locations of compression pad/tension tie location, compression pad geometry, and rotational position of compression pad/tension tie were examined. The experimental data highlighted in this paper are to be used to validate CFD tools that will be used to generate the flight aerothermodynamic database. Heat transfer measurements will also assist in the determination of the most appropriate engineering methods that will be used to assess local flight environments associated with protuberances/penetrations of the CEV thermal protection system.

Liechty, Derek S.↗

NASA NTRS2008

Effect of Protuberance Shape and Orientation on Space Shuttle Orbiter Boundary-Layer Transition

This document describes an experimental study conducted to examine the effects of protuberances on hypersonic boundary-layer transition. The experiment was conducted in the Langley 20-Inch Mach 6 Tunnel on a series of 0.9%-scale Shuttle Orbiter models. The data were acquired to complement the existing ground-based boundary-layer transition database that was used to develop Version 1.0 of the boundary-layer transition RTF (return-to-flight) tool. The existing ground-based data were all acquired on 0.75%-scale Orbiter models using diamond-shaped ( pizza-box ) trips. The larger model scale facilitated in manufacturing higher fidelity protuberances. The end use of this experimental database will be to develop a technical basis (in the form of a boundary-layer transition correlation) to assess representative protrusion shapes, e.g., gap fillers and protrusions resulting from possible tile repair concepts. The primary objective of this study is to investigate the effects of protuberance-trip location and geometry on Shuttle Orbiter boundary-layer transition. Secondary goals are to assess the effects of gap-filler orientation and other protrusion shapes on boundary-layer transition. Global heat-transfer images using phosphor thermography of the Orbiter windward surface and the corresponding streamwise and spanwise heating distributions were used to infer the state of the boundary layer, i.e., laminar, transitional, or turbulent.

King, RUdolph A.↗

NASA NTRS2007

Pressure Gradient Effects on Hypersonic Cavity Flow Heating

Everhart, Joel L.↗