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NASA NTRS1997

Study of SRM Critical Surfaces Using Near Infrared Optical Fiber Spectrometry

The measurement and control of cleanliness for critical surfaces during manufacturing and in service operations provides a unique challenge in the current thrust for environmentally benign processes. Of particular interest has been work performed in maintaining quality in the production of bondline surfaces in propulsion systems and the identification of possible contaminants which are detrimental to the integrity of the bondline. This work requires an in-depth study of the possible sources of contamination, methodologies to identify contaminants, discrimination between contaminants and chemical species caused by environment, and the effect of particular contaminants on the bondline integrity of the critical surfaces. This paper will provide an introduction to the use of Near Infrared (NIR) optical fiber spectrometry in a nondestructive measurement system for process monitoring and how it can be used to help clarify issues concerning surface chemistry. In a previous conference, experimental results for quantitative measurement of silicone and Conoco HD2 greases, and tape residues on solid rocket motor surfaces were presented. This paper will present data for metal hydroxides and discuss the use of the integrating sphere to minimize the effects of physical properties of the surfaces (such as surface roughness) on the results obtained from the chemometric methods used for quantitative analysis.

Workman, G. L.↗

NASA NTRSDate not supplied

NDE Methods and Capabilities Handbook - Resources for the Composites NDE Community

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA’s Advanced Composites Project, a public-private partnership between government, universities and industry, sought to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites was one of the three focused research areas of the project. One deliverable of the project was to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publicly available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate carbon fiber reinforced polymer composite (CFRP) structures. The Handbook seeks to reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. Techniques include, but are not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types include, but are not limited to porosity, delaminations, voids, Automated Fiber Placement (AFP) defects and impact damage. The Handbook contains details such as inspection parameters, data analysis techniques, inspection efficiency and limitations. This presentation will describe key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members. Availability to the NDE community of the fabricated NDE standards as well as the raw data collected on the standards by the Consortium members is discussed.

Nondestructive Evaluation↗

NASA NTRS1997

Ultrasonic Nondestructive Evaluation Techniques Applied to the Quantitative Characterization of Textile Composite Materials

In this Progress Report, we describe our further development of advanced ultrasonic nondestructive evaluation methods applied to the characterization of anisotropic materials. We present images obtained from experimental measurements of ultrasonic diffraction patterns transmitted through water only and transmitted through water and a thin woven composite. All images of diffraction patterns have been included on the accompanying CD-ROM in the JPEG format and Adobe TM Portable Document Format (PDF), in addition to the inclusion of hardcopies of the images contained in this report. In our previous semi-annual Progress Report (NAG 1-1848, December, 1996), we proposed a simple model to simulate the effect of a thin woven composite on an insonifying ultrasonic pressure field. This initial approach provided an avenue to begin development of a robust measurement method for nondestructive evaluation of anisotropic materials. In this Progress Report, we extend that work by performing experimental measurements on a single layer of a five-harness biaxial woven composite to investigate how a thin, yet architecturally complex, material interacts with the insonifying ultrasonic field. In Section 2 of this Progress Report we describe the experimental arrangement and methods for data acquisition of the ultrasonic diffraction patterns upon transmission through a thin woven composite. We also briefly describe the thin composite specimen investigated. Section 3 details the analysis of the experimental data followed by the experimental results in Section 4. Finally, a discussion of the observations and conclusions is found in Section 5.

Miller, James G.↗

NASA NTRS2010

Investigating Premature Ignition of Thruster Pressure Cartridges by Mechanical Impact of Internal Components

Pyrotechnic thruster pressure cartridges (TPCs) are used for aeroshell separation on a new NASA crew launch vehicle. The premature ignition concern was hypothesized based on the potential range of motion of the subassemblies, projected worst case accelerations, and the internal geometry that could subject propellant grains to mechanical impact sufficiently high for ignition. This possibility was investigated by fabricating a high-fidelity model of the suspected contact geometry, placing a representative amount of propellant in it, and impacting the propellant with a range of forces equivalent to and greater than the maximum possible during launch. Testing demonstrated that the likelihood of ignition is less than 1 in 1,000,000. The test apparatus, methodology, and results are described in this paper. Nondestructive evaluation ( NDE) during TPC acceptance testing indicated that internal assemblies moved during shock and vibration testing due to an internal bond anomaly. This caused concerns that the launch environment might produce the same movement and release propellant grains that might be prematurely ignited through impact or through electrostatic discharge (ESD) as grains vibrated against internal surfaces. Since a new lot could not be fabricated in time, a determination had to be made as to whether the lot was acceptable to fly. This paper discusses the analysis and impact testing used to address the potential impact issue and a separate paper addresses the ESD issue.

Woods, Stephen S.↗

NASA NTRS1978

Study of solar cell welds

The thermal imaging technique was evaluated for its capabilities in the nondestructive evaluation of solar cell welds. The temperature and spatial resolution of state of the art instrumentation was sufficient for both qualitative and quantitative determination of the quality of solar cell welds. The addition of color digitized thermography enhanced the aspects of the thermographic display and allowed easily computerized testing procedures. For automated testing systems an accurate correlation of weld quality with temperature profiles of the welds needs to be performed. In comparison, the holographic technique was complementary with the thermal imaging technique, except that the holographic analysis appeared to be more quantitative at the present time. However, the thermal imaging approach is much more versatile in overall capabilities.

Workman, G. L.↗

NASA NTRS1978

Quantitative ultrasonic evaluation of mechanical properties of engineering materials

Current progress in the application of ultrasonic techniques to nondestructive measurement of mechanical strength properties of engineering materials is reviewed. Even where conventional NDE techniques have shown that a part is free of overt defects, advanced NDE techniques should be available to confirm the material properties assumed in the part's design. There are many instances where metallic, composite, or ceramic parts may be free of critical defects while still being susceptible to failure under design loads due to inadequate or degraded mechanical strength. This must be considered in any failure prevention scheme that relies on fracture analysis. This review will discuss the availability of ultrasonic methods that can be applied to actual parts to assess their potential susceptibility to failure under design conditions.

Vary, A.↗

NASA NTRS2006

High-Performance Scanning Acousto-Ultrasonic System

A high-performance scanning acousto-ultrasonic system, now undergoing development, is designed to afford enhanced capabilities for imaging microstructural features, including flaws, inside plate specimens of materials. The system is expected to be especially helpful in analyzing defects that contribute to failures in polymer- and ceramic-matrix composite materials, which are difficult to characterize by conventional scanning ultrasonic techniques and other conventional nondestructive testing techniques. Selected aspects of the acousto-ultrasonic method have been described in several NASA Tech Briefs articles in recent years. Summarizing briefly: The acousto-ultrasonic method involves the use of an apparatus like the one depicted in the figure (or an apparatus of similar functionality). Pulses are excited at one location on a surface of a plate specimen by use of a broadband transmitting ultrasonic transducer. The stress waves associated with these pulses propagate along the specimen to a receiving transducer at a different location on the same surface. Along the way, the stress waves interact with the microstructure and flaws present between the transducers. The received signal is analyzed to evaluate the microstructure and flaws. The specific variant of the acousto-ultrasonic method implemented in the present developmental system goes beyond the basic principle described above to include the following major additional features: Computer-controlled motorized translation stages are used to automatically position the transducers at specified locations. Scanning is performed in the sense that the measurement, data-acquisition, and data-analysis processes are repeated at different specified transducer locations in an array that spans the specimen surface (or a specified portion of the surface). A pneumatic actuator with a load cell is used to apply a controlled contact force. In analyzing the measurement data for each pair of transducer locations in the scan, the total (multimode) acousto-ultrasonic response of the specimen is utilized. The analysis is performed by custom software that extracts parameters of signals in the time and frequency domains. The computer hardware and software provide both real-time and postscan processing and display options. For example, oscilloscope displays of waveforms and power spectral densities are available in real time. Images can be computed while scanning continues. Signals can be digitally preprocessed and/or post-processed by filtering, windowing, time-segmenting, and running-waveform-averaging algorithms. In addition, the software affords options for off-line simulation of the waveform-data-acquisition and scanning processes. In tests, the system has been shown to be capable of characterizing microstructural changes and defects in SiC/SiC and C/SiC ceramic-matrix composites. Delaminations, variations in density, microstructural changes attributable to infiltration by silicon, and crack-space indications (defined in the next sentence) have been revealed in images formed from several time- and frequency-domain parameters of scanning acousto-ultrasonic signals. The crack-space indications were image features that were not revealed by other nondestructive testing methods and are so named because they turned out to mark locations where cracking eventually occurred.

Roth, Don↗

NASA NTRS1972

Failure analysis of solid rocket apogee motors

The analysis followed five selected motors through initial design, development, test, qualification, manufacture, and final flight reports. An audit was conducted at the manufacturing plants to complement the literature search with firsthand observations of the current philosophies and practices that affect reliability of the motors. A second literature search emphasized acquisition of spacecraft and satellite data bearing on solid motor reliability. It was concluded that present practices at the plants yield highly reliable flight hardware. Reliability can be further improved by new developments of aft-end bonding and initiator/igniter nondestructive test methods, a safe/arm device, and an insulation formulation. Minimum diagnostic instrumentation is recommended for all motor flights. Surplus motors should be used in margin testing. Criteria should be established for pressure and zone curing. The motor contractor should be represented at launch. New design analyses should be made of stretched motors and spacecraft/motor pairs.

Martin, P. J.↗

NASA NTRSDate not supplied

Recent Advances in LIBS for Real-Time Detection of Silicone Contaminants on CFRP Surfaces

Laser induced breakdown spectroscopy (LIBS) is a materials characterization technique that has been advanced and refined to provide in situ, real-time quality control of carbon fiber reinforced polymer (CFRP) surfaces. As part of an effort to improve process control for adhesive bonding, aLIBS system was designed and assembled at the NASA Langley Research Center (LaRC) to enable detection of ultra low concentrations of silicone contamination on CFRP adherends. The LIBS instrument provides high sensitivity detection and quasi-nondestructive surface characterization ofCFRP adherends prior to adhesive bonding. This review focuses on the advancements at LaRC using LIBS as a quality control tool for the detection of silicone contaminants for improved adhesive bonding reliability of CFRP materials. This work describes how the LIBS technique was advanced by analyzing the laser parameters, studying the laser-matter interactions, and performing time-resolved measurements to determine the optimal plasma conditions for elemental detection. In addition, LIBS results were compared to X-ray photoelectron spectroscopy data to enable quantitative analysis from analytical calibration curves. Examples are shown of how to perform surface mapping of silicone contamination. Finally, a brief discussion is presented on LIBS instrumentation, recommendations for laser parameters and instrumentation components, and LIBS technique maturity

Rodolfo I. Ledesma↗

NASA NTRS2011

Three Dimensional Structures of Particles Recovered from the Asteroid Itokawa by the Hayabusa Mission and a Role of X-Ray Microtomography in the Preliminary Examination

Particles of regolith on S-type Asteroid 25143 Itokawa were successfully recovered by the Hayabusa mission of JAXA (Japan Aerospace Exploration Agency). Near-infrared spectral study of Itokawa s surface indicates that these particles are materials similar to LL5 or LL6 chondrites. High-resolution images of Itokawa's surface suggest that they may be breccias and some impact products. At least more than 1500 particles were identified as Itokawa origin at curation facility of JAXA. Preliminary analysis with SEM/EDX at the curation facility shows that they are roughly similar to LL chondrites. Although most of them are less than 10 micron in size, some larger particles of about 100 micron or larger were also identified. A part of the sample (probably several tens particles) will be selected by Hayabusa sample curation team, and sequential examination will start from January 2011 by Hayabusa Asteroidal Sample Preliminary Examination Team (HASPET). In mainstream of the analytical flow, each particle will be examined by microtomography, XRD and XRF first as nondestructive analyses, and then the particle will be cut by an ultra-microtome and examined by TEM, SEM, EPMA, SIMS, PEEM/XANES, and TOF-SIMS sequentially. Three-dimensional structures of Itokawa particles will be obtained by microtomography sub-team of HASPET. The results together with XRD and XRF will be used for design of later destructive analyses, such as determination of cutting direction and depth, to obtain as much information as possible from small particles. Scientific results and a role of the microtomography in the preliminary examination will be presented.

Tsuchiyama, A.↗

NASA NTRSDate not supplied

Recent Advances in LIBS for Real-Time Detection of Silicone Contaminants on CFRP Surfaces

Laser induced breakdown spectroscopy (LIBS) is a materials characterization technique that has been advanced and refined to provide in situ, real-time quality control of carbon fiber reinforced polymer (CFRP) surfaces. As part of an effort to improve process control for adhesive bonding, a LIBS system was designed and assembled at NASA Langley Research Center (LaRC) to enable detection of ultralow concentrations of silicone contamination on CFRP adherends. The LIBS instrument provides high sensitivity detection and quasi-nondestructive surface characterization of CFRP adherends prior to adhesive bonding. This review focuses on the advancements at LaRC using LIBS as a quality control tool for the detection of silicone contaminants for improved adhesive bonding reliability of CFRP materials. This work describes how the LIBS technique was advanced by analyzing the laser parameters, studying the laser-matter interactions, and performing time-resolved measurements to determine the optimal plasma conditions for elemental detection. In addition, LIBS results were compared to X-ray photoelectron spectroscopy data to enable quantitative analysis from analytical calibration curves. Examples are shown of how to perform surface mapping of silicone contamination. Finally, a brief discussion is also presented on LIBS instrumentation, recommendations for laser parameters and instrumentation components, and LIBS technique maturity.

Surface characterization, Carbon fiber reinforced ↗

NASA NTRS1982

Evaluation of solar cell welds by scanning acoustic microscopy

Scanning laser acoustic microscopy was used to nondestructively evaluate solar cell interconnect bonds made by resistance welding. Both copper-silver and silver-silver welds were analyzed. The bonds were produced either by a conventional parallel-gap welding technique using rectangular electrodes or new annular gap design with a circular electrode cross section. With the scanning laser acoustic microscope, it was possible to produce a real time television image which reveales the weld configuration as it relates to electrode geometry. The effect of electrode misalinement with the surface of the cell was also determined. A preliminary metallographic analysis was performed on selected welds to establish the relationship between actual size and shape of the weld area and the information available from acoustic micrographs.

Klima, S. J.↗

NASA NTRS1999

3-D Surface Depression Profiling Using High Frequency Focused Air-Coupled Ultrasonic Pulses

Surface topography is an important variable in the performance of many industrial components and is normally measured with diamond-tip profilometry over a small area or using optical scattering methods for larger area measurement. This article shows quantitative surface topography profiles as obtained using only high-frequency focused air-coupled ultrasonic pulses. The profiles were obtained using a profiling system developed by NASA Glenn Research Center and Sonix, Inc (via a formal cooperative agreement). (The air transducers are available as off-the-shelf items from several companies.) The method is simple and reproducible because it relies mainly on knowledge and constancy of the sound velocity through the air. The air transducer is scanned across the surface and sends pulses to the sample surface where they are reflected back from the surface along the same path as the incident wave. Time-of-flight images of the sample surface are acquired and converted to depth/surface profile images using the simple relation (d = V*t/2) between distance (d), time-of-flight (t), and the velocity of sound in air (V). The system has the ability to resolve surface depression variations as small as 25 microns, is useable over a 1.4 mm vertical depth range, and can profile large areas only limited by the scan limits of the particular ultrasonic system. (Best-case depth resolution is 0.25 microns which may be achievable with improved isolation from vibration and air currents.) The method using an optimized configuration is reasonably rapid and has all quantitative analysis facilities on-line including 2-D and 3-D visualization capability, extreme value filtering (for faulty data), and leveling capability. Air-coupled surface profilometry is applicable to plate-like and curved samples. In this article, results are shown for several proof-of-concept samples, plastic samples burned in microgravity on the STS-54 space shuttle mission, and a partially-coated cylindrical ceramic composite sample. Impressive results were obtained for all samples when compared with diamond-tip profiles and measurements from micrometers. The method is completely nondestructive, noninvasive, non-contact and does not require light-reflective surfaces.

Roth, Don J.↗

NASA NTRS2019

Reducing Aviation Fuel Costs with Non-Destructive Testing

Thermal barrier coatings (TBCs) are absolutely critical to the efficient and safe operation of gas turbine engines (GTEs). Manufacturing TBCs is a complex chemical, thermal and mechanical process that requires precise control. And yet, the variation in life of a TBC operated within a GTE is large. This variation ultimately reduces operational performance via a designed reduction to the turbine entry temperature, T4.This paper makes the case for developing advanced THz and sub-millimeter based nondestructive testing (NDT) techniques, capable of estimating when TBC components will fail. Such a technique could identify TBCs with low expected remaining useful lifetimes, directly after production. These TBCs could be re-manufactured, thereby not only improving their own expected useful life, but also the mean lifetime of the entire manufacturing population. A series of calculations demonstrates that TBCs with enhanced life characteristics can withstand higher T4 temperatures. Assuming that a GTE is to operate at a constant thrust, this increased temperature can be traded for a reduction in fuel flow. An analysis comparing fuel savings to manufacturing costs shows that substantial savings are achievable.

microwaves↗

NASA NTRS2010

Search for Organic Nanoglobules in Carbonaceous Chondrites Using Microtomography

Primitive solar materials have various organic matters. In recent years, novel organic materials called organic nanoglobules of a few hundred micrometers in typical size were discovered in carbonaceous chondrites, IDPs, and comet 81P/Wild 2. The organic globules are spherical shape and in many cases with hollow structures. Composition of the globules are mainly aromatic carbon. The isotopic anomalies of SD and 6N 15 observed in the globules indicate that they were formed from photochemical reaction to ice particles at very low temperature environment, such as molecular clouds or outer protosolar disk. Aqueous alteration of organic matters and the gamma-ray irradiation to PAH are also suggested as alternative possible formation processes. If the globules are made from organic ice particles, the hollow regions of the globules are suggested to be once filled with volatile H20-rich organic ices, while if they were formed by aqueous alteration, the hollow regions should be filled with a fluid which caused the aqueous alteration. However, fluids in the globules have not been detected so far in the previous studies. If fluids were originally preserved in the hollows, they might be lost during destructive processes of sample separation or preparation for TEM observation. X-ray computed tomography (CT) is a nondestructive method which can determine 3-D internal structures of objects. SR (synchrotron radiation)-based imaging microtomography can give submicron spatial resolution [8] and was applied to micro textures in extraterrestrial materials, such as cometary grains captured by the Stardust mission [9]. If organic globules are observed non-destructively in carbonaceous chondrites by tomography, we can check the presence of fluids in the hollows. If fluids are preserved, we may analyze chemical and isotopic compositions of the fluids. The purpose of this study is to observe organic nanoglobules using imaging tomography for future analysis.

Matsumoto, T.↗

NASA NTRS2004

Vibration-Based Method Developed to Detect Cracks in Rotors During Acceleration Through Resonance

In recent years, there has been an increasing interest in developing rotating machinery shaft crack-detection methodologies and online techniques. Shaft crack problems present a significant safety and loss hazard in nearly every application of modern turbomachinery. In many cases, the rotors of modern machines are rapidly accelerated from rest to operating speed, to reduce the excessive vibrations at the critical speeds. The vibration monitoring during startup or shutdown has been receiving growing attention (ref. 1), especially for machines such as aircraft engines, which are subjected to frequent starts and stops, as well as high speeds and acceleration rates. It has been recognized that the presence of angular acceleration strongly affects the rotor's maximum response to unbalance and the speed at which it occurs. Unfortunately, conventional nondestructive evaluation (NDE) methods have unacceptable limits in terms of their application for online crack detection. Some of these techniques are time consuming and inconvenient for turbomachinery service testing. Almost all of these techniques require that the vicinity of the damage be known in advance, and they can provide only local information, with no indication of the structural strength at a component or system level. In addition, the effectiveness of these experimental techniques is affected by the high measurement noise levels existing in complex turbomachine structures. Therefore, the use of vibration monitoring along with vibration analysis has been receiving increasing attention.

Sawicki, Jerzy T.↗

NASA NTRSDate not supplied

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 NTRS2006

Test and Analysis of Foam Impacting a 6x6 Inch RCC Flat Panel

This report presents the testing and analyses of a foam projectile impacting onto thirteen 6x6 inch flat panels at a 90 degrees incidence angle. The panels tested in this investigation were fabricated of Reinforced-Carbon-Carbon material and were used to aid in the validation of an existing material model, MAT58. The computational analyses were performed using LS-DYNA, which is a physics-based, nonlinear, transient, finite element code used for analyzing material responses subjected to high impact forces and other dynamic conditions. The test results were used to validate LS-DYNA predictions and to determine the threshold of damage generated by the MAT58 cumulative damage material model. The threshold of damage parameter represents any external or internal visible RCC damage detectable by nondestructive evaluation techniques.

Lessard, Wendy B.↗