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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Health Monitoring of a Rotating Disk Using a Combined Analytical-Experimental Approach

Rotating disks undergo rigorous mechanical loading conditions that make them subject to a variety of failure mechanisms leading to structural deformities and cracking. During operation, periodic loading fluctuations and other related factors cause fractures and hidden internal cracks that can only be detected via noninvasive types of health monitoring and/or nondestructive evaluation. These evaluations go further to inspect material discontinuities and other irregularities that have grown to become critical defects that can lead to failure. Hence, the objectives of this work is to conduct a collective analytical and experimental study to present a well-rounded structural assessment of a rotating disk by means of a health monitoring approach and to appraise the capabilities of an in-house rotor spin system. The analyses utilized the finite element method to analyze the disk with and without an induced crack at different loading levels, such as rotational speeds starting at 3000 up to 10 000 rpm. A parallel experiment was conducted to spin the disk at the desired speeds in an attempt to correlate the experimental findings with the analytical results. The testing involved conducting spin experiments which, covered the rotor in both damaged and undamaged (i.e., notched and unnotched) states. Damaged disks had artificially induced through-thickness flaws represented in the web region ranging from 2.54 to 5.08 cm (1 to 2 in.) in length. This study aims to identify defects that are greater than 1.27 cm (0.5 in.), applying available means of structural health monitoring and nondestructive evaluation, and documenting failure mechanisms experienced by the rotor system under typical turbine engine operating conditions.

Abdul-Aziz, Ali↗
NASA NTRS2001

Training Data Optimized and Conditioned to Learn Characteristic Patterns of Vibrating Blisks and Fan Blades

At the NASA Glenn Research Center, we have been training artificial neural networks to interpret the characteristic patterns (see the leftmost image) generated from electronic holograms of vibrating structures. These patterns not only visualize the vibration properties of structures, but small changes in the patterns can indicate structural changes, cracking, or damage. Neural networks detect these small changes well. Our objective has been to adapt the neural-network, electronic-holography combination for inspecting components in Glenn's Spin Rig.

Decker, Arthur J.↗
NASA NTRS2004

Formulations for Stronger Solid Oxide Fuel-Cell Electrolytes

Tests have shown that modification of chemical compositions can increase the strengths and fracture toughnesses of solid oxide fuel-cell (SOFC) electrolytes. Heretofore, these solid electrolytes have been made of yttria-stabilized zirconia, which is highly conductive for oxygen ions at high temperatures, as needed for operation of fuel cells. Unfortunately yttria-stabilized zirconia has a high coefficient of thermal expansion, low resistance to thermal shock, low fracture toughness, and low mechanical strength. The lack of strength and toughness are especially problematic for fabrication of thin SOFC electrolyte membranes needed for contemplated aeronautical, automotive, and stationary power-generation applications. The modifications of chemical composition that lead to increased strength and fracture toughness consist in addition of alumina to the basic yttria-stabilized zirconia formulations. Techniques for processing of yttria-stabilized zirconia/alumina composites containing as much as 30 mole percent of alumina have been developed. The composite panels fabricated by these techniques have been found to be dense and free of cracks. The only material phases detected in these composites has been cubic zirconia and a alumina: this finding signifies that no undesired chemical reactions between the constituents occurred during processing at elevated temperatures. The flexural strengths and fracture toughnesses of the various zirconia-alumina composites were measured in air at room temperature as well as at a temperature of 1,000 C (a typical SOFC operating temperature). The measurements showed that both flexural strength and fracture toughness increased with increasing alumina content at both temperatures. In addition, the modulus of elasticity and the thermal conductivity were found to increase and the density to decrease with increasing alumina content. The oxygen-ion conductivity at 1,000 C was found to be unchanged by the addition of alumina.

Bansal, Narottam P.↗
NASA NTRS1971

Development of nondestructive testing techniques for plated-through holes in multilayer printed circuit boards

The development of a nondestructive test with the capability to interrogate plated-through holes as small as 0.51 millimeters inside diameter is discussed. The system can detect defects such as holes, voids, cracks, and thin spots that reduce the current carrying capability of plates-through interconnects by 20 percent or more. Efforts were directed toward the design and fabrication of magnetic circuitry mutual coupling probes and to evaluate the effectiveness of these devices for detecting in multilayer board plated-through holes.

Anthony, P. L.↗
NASA NTRS2014

Cyclic Crack Growth Testing of an A.O. Smith Multilayer Pressure Vessel with Modal Acoustic Emission Monitoring and Data Assessment

Digital Wave Corp. (DWC) was retained by Jacobs ATOM at NASA Ames Research Center to perform cyclic pressure crack growth sensitivity testing on a multilayer pressure vessel instrumented with DWC's Modal Acoustic Emission (MAE) system, with captured wave analysis to be performed using DWCs WaveExplorerTM software, which has been used at Ames since 2001. The objectives were to document the ability to detect and characterize a known growing crack in such a vessel using only MAE, to establish the sensitivity of the equipment vs. crack size and / or relevance in a realistic field environment, and to obtain fracture toughness materials properties in follow up testing to enable accurate crack growth analysis. This report contains the results of the testing.

Ziola, Steven M.↗
NASA NTRS2000

Lack of Penetration in Friction Stir Welds: Effects on Mechanical Properties and NDE Feasibility

This presentation reviews the issue of lack of penetration (LOP) in Friction Stir Welding and the feasibility of using non-destructive tests to detect . Friction Stir Welding takes place in the solid phase below the melting point of the materials to be joined. It thus gives the ability to join materials which are difficult to fusion weld, for example 2000 and 7000 aluminium alloys. This process though can result in a lack of penetration, due to an incomplete penetration of the DXZ. This is frequently referred to as a "kissing bond", which requires micro examination to detect. The presentation then discusses the surface crack tension tests. It then reviews the simulated service test and results. It then discusses the feasibility of using non-destructive examination to detect LOP, the forms of test which can be used, and the results the tests.

Kinchen, David G.↗
NASA NTRS2010

Back-Face Strain for Monitoring Stable Crack Extension in Precracked Flexure Specimens

Calibrations relating back-face strain to crack length in precracked flexure specimens were developed for different strain gage sizes. The functions were verified via experimental compliance measurements of notched and precracked ceramic beams. Good agreement between the functions and experiments occurred, and fracture toughness was calculated via several operational methods: maximum test load and optically measured precrack length; load at 2 percent crack extension and optical precrack length; maximum load and back-face strain crack length. All the methods gave vary comparable results. The initiation toughness, K(sub Ii) , was also estimated from the initial compliance and load.The results demonstrate that stability of precracked ceramics specimens tested in four-point flexure is a common occurrence, and that methods such as remotely-monitored load-point displacement are only adequate for detecting stable extension of relatively deep cracks.

Salem, Jonathan A.↗
NASA NTRS2011

Detecting Damage in Ceramic Matrix Composites Using Electrical Resistance

The majority of damage in SiC/SiC ceramic matrix composites subjected to monotonic tensile loads is in the form of distributed matrix cracks. These cracks initiate near stress concentrations, such as 90 deg fiber tows or large matrix pores and continue to accumulate with additional stress until matrix crack saturation is achieved. Such damage is difficult to detect with conventional nondestructive evaluation techniques (immersion ultrasonics, x-ray, etc.). Monitoring a specimen.s electrical resistance change provides an indirect approach for monitoring matrix crack density. Sylramic-iBN fiber- reinforced SiC composites with a melt infiltrated (MI) matrix were tensile tested at room temperature. Results showed an increase in resistance of more than 500% prior to fracture, which can be detected either in situ or post-damage. A relationship between resistance change and matrix crack density was also determined.

Smith, Craig E.↗
NASA NTRS2011

Probability of Detection (POD) Demonstration Transferability

NASA Special Level POD demonstration tests are typically performed on flat plates of a single material containing fatigue cracks with aspect rations between 0.3 and 0.5. Subsequent fracture mechanics analyses consider aspect ratios that range from 0.1 to 0.5. There is debate within the NDE community about the detectability of shallow cracks associated with NASA Special Level penetrant inspections that are routinely performed by propellant tank manufactures. The objective of the task is to investigate effect of crack aspect ratio on POD crack sizes for the penetrant inspection technique.

Parker, Bradford H.↗
NASA NTRS2003

Simulating Fatigue Crack Growth in Spiral Bevel Pinion

This project investigates computational modeling of fatigue crack growth in spiral bevel gears. Current work is a continuation of the previous efforts made to use the Boundary Element Method (BEM) to simulate tooth-bending fatigue failure in spiral bevel gears. This report summarizes new results predicting crack trajectory and fatigue life for a spiral bevel pinion using the Finite Element Method (FEM). Predicting crack trajectories is important in determining the failure mode of a gear. Cracks propagating through the rim may result in catastrophic failure, whereas the gear may remain intact if one tooth fails and this may allow for early detection of failure. Being able to predict crack trajectories is insightful for the designer. However, predicting growth of three-dimensional arbitrary cracks is complicated due to the difficulty of creating three-dimensional models, the computing power required, and absence of closed- form solutions of the problem. Another focus of this project was performing three-dimensional contact analysis of a spiral bevel gear set incorporating cracks. These analyses were significant in determining the influence of change of tooth flexibility due to crack growth on the magnitude and location of contact loads. This is an important concern since change in contact loads might lead to differences in SIFs and therefore result in alteration of the crack trajectory. Contact analyses performed in this report showed the expected trend of decreasing tooth loads carried by the cracked tooth with increasing crack length. Decrease in tooth loads lead to differences between SIFs extracted from finite element contact analysis and finite element analysis with Hertz contact loads. This effect became more pronounced as the crack grew.

Ural, Ani↗
NASA NTRS1986

Nondestructive Evaluation (NDE) of structural ceramics by photoacoustic microscopy

Photoacoustic microscopy (PAM) was utilized to detect surface and subsurface defects in structural ceramic materials. A computerized PAM data acquisition, color imaging and analysis system was developed and used. Subsurface simulated cylindrical holes can be detected to about 1 mm below the interrograting surface. Simulated tight surface cracks of 96 microns length and 48 microns depth can be detected in these materials under optimum conditions.

Khandelwal, P. K.↗
NASA NTRS2005

Development of Detectability Limits for On-Orbit Inspection of Space Shuttle Wing Leading Edge

At the conclusion of the Columbia Accident Investigation, one of the recommendations of the Columbia Accident Investigation Board (CAIB) was that NASA develop and implement an inspection plan for the Reinforced Carbon-Carbon (RCC) system components of the Space Shuttle. To address these issues, a group of scientists and engineers at NASA Langley Research Center proposed the use of an IR camera to inspect the RCC. Any crack in an RCC panel changes the thermal resistance of the material in the direction perpendicular to the crack. The change in thermal resistance can be made visible by introducing a heat flow across the crack and using an IR camera to image the resulting surface temperature distribution. The temperature difference across the crack depends on the change in the thermal resistance, the length of the crack, the local thermal gradient, and the rate of radiation exchange with the environment. This paper describes how the authors derived the minimum thermal gradient detectability limits for a through crack in an RCC panel. This paper will also show, through the use of a transient, 3-dimensional, finite element model, that these minimum gradients naturally exist on-orbit. The results from the finite element model confirm that there are sufficient thermal gradient to detect a crack on 96% of the RCC leading edge.

Stephan, Ryan A.↗
NASA NTRS2002

Fatigue Crack Measurement in Composite Materials by Ultrasonic Methods

The nondestructive detection of intra-ply microcracking in unlined pressure vessels fabricated from composite materials is critical to ensuring mission success. Microcracking in composite structures due to combined fatigue and cryogenic thermal loading can be very troublesome to detect in-service and when it begins to link through the thickness can cause leakage and failure of the structure. These leaks may lead to loss of pressure/propellant, increased risk of explosion and possible cryo-pumping. The work presented herein develops a method and an instrument to locate and measure intraply fatigue cracking through the thickness of laminated composite material by means of correlation with ultrasonic resonance. Resonant ultrasound spectroscopy provides measurements which are, sensitive to both the microscopic and macroscopic properties of an object. Elastic moduli, acoustic attenuation, and geometry can all be probed. The approach is based on the premise of half-wavelength resonance. The method injects a broadband ultrasonic wave into the test structure using a swept frequency technique. This method provides dramatically increased energy input into the test article, as compared to conventional spike pulsed ultrasonics. This relative energy increase improves the ability to measure finer details in the materials character, such as micro-cracking and porosity. As the micro-crack density increases, more interactions occur with the higher frequency (small wavelength) components of the signal train causing the spectrum to shift toward lower frequencies. Preliminary experiments have verified a measurable effect on the resonance spectrum of the ultrasonic data to detect microcracking. Methods involving self organizing neural networks and other clustering algorithms show that the resonance ultrasound signatures from composites vary with the degree of microcracking and can be separated and identified.

Walker, James L.↗
NASA NTRS1982

Recognizing defects in carbon-fiber reinforced plastics

The damage tolerance of structures made of carbon-fiber-reinforced plastic is tested under various loads. Test laminate (73/1/1, 24/9/1, 1465 A) specimens of thickness 1.5-3.2 mm with various defects were subjected to static and dynamic loads. Special attention was given to delamination, and ultrasonic C-scans were made on the specimens. It was shown that cracks from even small defects are detected with great accuracy. The same probes were also X rayed; defects that could not be detected under ordinary X rays were bored and studied under vacuum by a contrast technique. The nondestructive ultrasonic and X ray tests were controlled by partially destructive tests, and good agreement was observed.

Schuetze, R.↗
NASA NTRS1993

Autonomous Deicing System For Airplane Wing

Prototype autonomous deicing system for airplane includes network of electronic and electromechanical modules at various locations in wings and connected to central data-processing unit. Small, integrated solid-state device, using long coils installed under leading edge, exciting small vibrations to detect ice and larger vibrations to knock ice off. In extension of concept, outputs of vibration sensors and other sensors used to detect rivet-line fractures, fatigue cracks, and other potentially dangerous defects.

Hickman, G. A.↗
NASA NTRS1959

Exploratory Investigation of Advanced-Temperature Nickel-Base Alloys

An investigation was conducted to provide an advanced-temperature nickel-base alloy with properties suitable for aircraft turbine blades as well as for possible space vehicle applications. An entire series of alloys that do not require vacuum melting techniques and that generally provide good stress-rupture and impact properties was evolved. The basic-alloy composition of 79 percent nickel, 8 percent molybdenum, 6 percent chromium, 6 percent aluminum, and 1 percent zirconium was modified by a series of element additions such as carbon, titanium, and boron, with the nickel content adjusted to account for the additives. Stress-rupture, impact, and swage tests were made with all the alloys. The strongest composition (basic alloy plus 1.5 percent titanium plus 0.125 percent carbon) displayed 384- and 574-hour stress-rupture lives at 1800 F and 15,000 psi in the as-cast and homogenized conditions, respectively. All the alloys investigated demonstrated good impact resistance. Several could not be broken in a low-capacity Izod impact tester and, on this basis, all compared favorably with several high-strength high-temperature alloys. Swaging cracks were encountered with all the alloys. In several cases, however, these cracks were slight and could be detected only by zyglo examination. Some of these compositions may become amenable to hot working on further development. On the basis of the properties indicated, it appears that several of the alloys evolved, particularly the 1.5 percent titanium plus 0.125 percent carbon basic-alloy modification, could be used for advanced- temperature turbine blades, as well as for possible space vehicle applications.

Freche, John C.↗
NASA NTRS2010

Acoustic Emission Measurement with Fiber Bragg Gratings for Structure Health Monitoring

Structural Health monitoring (SHM) is a way of detecting and assessing damage to large scale structures. Sensors used in SHM for aerospace structures provide real time data on new and propagating damage. One type of sensor that is typically used is an acoustic emission (AE) sensor that detects the acoustic emissions given off from a material cracking or breaking. The use of fiber Bragg grating (FBG) sensors to provide acoustic emission data for damage detection is studied. In this research, FBG sensors are used to detect acoustic emissions of a material during a tensile test. FBG sensors were placed as a strain sensor (oriented parallel to applied force) and as an AE sensor (oriented perpendicular to applied force). A traditional AE transducer was used to collect AE data to compare with the FBG data. Preliminary results show that AE with FBGs can be a viable alternative to traditional AE sensors.

Banks, Curtis E.↗