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NASA NTRS2001

Rapid Prototyping Integrated With Nondestructive Evaluation and Finite Element Analysis

Most reverse engineering approaches involve imaging or digitizing an object then creating a computerized reconstruction that can be integrated, in three dimensions, into a particular design environment. Rapid prototyping (RP) refers to the practical ability to build high-quality physical prototypes directly from computer aided design (CAD) files. Using rapid prototyping, full-scale models or patterns can be built using a variety of materials in a fraction of the time required by more traditional prototyping techniques (refs. 1 and 2). Many software packages have been developed and are being designed to tackle the reverse engineering and rapid prototyping issues just mentioned. For example, image processing and three-dimensional reconstruction visualization software such as Velocity2 (ref. 3) are being used to carry out the construction process of three-dimensional volume models and the subsequent generation of a stereolithography file that is suitable for CAD applications. Producing three-dimensional models of objects from computed tomography (CT) scans is becoming a valuable nondestructive evaluation methodology (ref. 4). Real components can be rendered and subjected to temperature and stress tests using structural engineering software codes. For this to be achieved, accurate high-resolution images have to be obtained via CT scans and then processed, converted into a traditional file format, and translated into finite element models. Prototyping a three-dimensional volume of a composite structure by reading in a series of two-dimensional images generated via CT and by using and integrating commercial software (e.g. Velocity2, MSC/PATRAN (ref. 5), and Hypermesh (ref. 6)) is being applied successfully at the NASA Glenn Research Center. The building process from structural modeling to the analysis level is outlined in reference 7. Subsequently, a stress analysis of a composite cooling panel under combined thermomechanical loading conditions was performed to validate this process.

Abdul-Aziz, Ali↗

NASA NTRS1993

Flight testing of a fiber optic temperature sensor

A fiber optic temperature sensor (FOTS) system consisting of an optical probe, a flexible fiber optic cable, and an electro-optic signal processor was fabricated to measure the gas temperature in a turbine engine. The optical probe contained an emissive source embedded in a sapphire lightguide coupled to a fiber-optic jumper cable and was retrofitted into an existing thermocouple probe housing. The flexible fiber optic cable was constructed with 200 micron core, polyimide-coated fiber and was ruggedized for an aircraft environment. The electro-optic signal processing unit was used to ratio the intensities of two wavelength intervals and provided an analog output value of the indicated temperature. Subsequently, this optical sensor system was installed on a NASA Dryden F-15 Highly Integrated Digital Electronic Control (HIDEC) Aircraft Engine and several flight tests were conducted. Over the course of flight testing, the FOTS system's response was proportional to the average of the existing thermocouples sensing the changes in turbine engine thermal conditions.

Finney, M. J.↗

NASA NTRS1987

Full-scale engine demonstration of an advanced sensor failure detection, isolation and accommodation algorithm: Preliminary results

The objective of the advanced detection, isolation, and accommodation (ADIA) program is to improve the overall demonstrated reliability of digital electronic control systems for turbine engines. For this purpose, algorithms were developed which detect, isolate, and accommodate sensor failures using analytical redundancy. Preliminary results of a full scale engine demonstration of the ADIA algorithm are presented. Minimum detectable levels of sensor failures for an F100 turbofan engine control system are determined and compared to those obtained during a previous evaluation of this algorithm using a real-time hybrid computer simulation of the engine.

Merrill, Walter C.↗

NASA NTRS1987

Full-scale engine demonstration of an advanced sensor failure detection isolation, and accommodation algorithm - Preliminary results

Merrill, Walter C.↗

NASA NTRS1998

NASA Image eXchange (NIX)

This paper discusses the technical aspects of and the project background for the NASA Image exchange (NIX). NIX, which provides a single entry point to search selected image databases at the NASA Centers, is a meta-search engine (i.e., a search engine that communicates with other search engines). It uses these distributed digital image databases to access photographs, animations, and their associated descriptive information (meta-data). NIX is available for use at the following URL: http://nix.nasa.gov./NIX, which was sponsored by NASAs Scientific and Technical Information (STI) Program, currently serves images from seven NASA Centers. Plans are under way to link image databases from three additional NASA Centers. images and their associated meta-data, which are accessible by NIX, reside at the originating Centers, and NIX utilizes a virtual central site that communicates with each of these sites. Incorporated into the virtual central site are several protocols to support searches from a diverse collection of database engines. The searches are performed in parallel to ensure optimization of response times. To augment the search capability, browse functionality with pre-defined categories has been built into NIX, thereby ensuring dissemination of 'best-of-breed' imagery. As a final recourse, NIX offers access to a help desk via an on-line form to help locate images and information either within the scope of NIX or from available external sources.

vonOfenheim. William H. C.↗

NASA NTRS2003

Structural Anomalies Detected in Ceramic Matrix Composites Using Combined Nondestructive Evaluation and Finite Element Analysis (NDE and FEA)

Most reverse engineering approaches involve imaging or digitizing an object and then creating a computerized reconstruction that can be integrated, in three dimensions, into a particular design environment. The rapid prototyping technique builds high-quality physical prototypes directly from computer-aided design files. This fundamental technique for interpreting and interacting with large data sets is being used here via Velocity2 (an integrated image-processing software, ref. 1) using computed tomography (CT) data to produce a prototype three-dimensional test specimen model for analyses. A study at the NASA Glenn Research Center proposes to use these capabilities to conduct a combined nondestructive evaluation (NDE) and finite element analysis (FEA) to screen pretest and posttest structural anomalies in structural components. A tensile specimen made of silicon nitrite (Si3N4) ceramic matrix composite was considered to evaluate structural durability and deformity. Ceramic matrix composites are being sought as candidate materials to replace nickel-base superalloys for turbine engine applications. They have the unique characteristics of being able to withstand higher operating temperatures and harsh combustion environments. In addition, their low densities relative to metals help reduce component mass (ref. 2). Detailed three-dimensional volume rendering of the tensile test specimen was successfully carried out with Velocity2 (ref. 1) using two-dimensional images that were generated via computed tomography. Subsequent, three-dimensional finite element analyses were performed, and the results obtained were compared with those predicted by NDE-based calculations and experimental tests. It was shown that Velocity2 software can be used to render a three-dimensional object from a series of CT scan images with a minimum level of complexity. The analytical results (ref. 3) show that the high-stress regions correlated well with the damage sites identified by the CT scans and the experimental data. Furthermore, modeling of the voids collected via NDE offered an analytical advantage that resulted in more accurate assessments of the material s structural strength. The top figure shows a CT scan image of the specimen test section illustrating various hidden structural entities in the material and an optical image of the test specimen considered in this study. The bottom figure represents the stress response predicted from the finite element analyses (ref .3 ) for a selected CT slice where it clearly illustrates the correspondence of the high stress risers due to voids in the material with those predicted by the NDE. This study is continuing, and efforts are concentrated on improving the modeling capabilities to imitate the structural anomalies as detected.

Abdul-Aziz, Ali↗

NASA NTRSDate not supplied

A Model-Based Framework for NASA Science Mission Formulation

This paper details an effort to implement NASA systems engineering standards and practices using a Digital System Model (DSM), which we also refer to as the system architecture model (SAM). Creating a SAM at the beginning of a design effort helps systems engineer identify errors, inconsistencies, and miscommunications as early as possible. Such issues can then be resolved before it becomes costly and requires significant rework to do so. A pre-formulation SAM also enables advanced trade studies at the earliest stage of concept development. This results in “win-wins” where architecture changes can reduce cost without decreasing effectiveness, or increase effectiveness without increasing cost. SAMs also streamline the creation of project documentation and facilitate superior dialogue between science, engineering, and management stakeholders. Common artifacts such as Master Equipment Lists (MELs), Science Traceability Matrices (STMs), and Mission Traceability Matrices (MTMs), can be automatically maintained through requirements and structural models in the SAM. Key performance parameters (and changes to them) can be tied to simulations in the SAM, allowing far more rapid and extensive trade space exploration. As will be shown in this work, these advantages have been realized for the first time in an actual NASA Goddard Space Flight Center (GSFC) pre-phase A and phase A concept study. Modelbased design tools have been developed in a general, modular manner to maximize reuse on future programs. Focus is placed on structural and requirements architecture modeling. Data is ingested into the SAM from existing discipline model outputs (e.g. MS Excel spreadsheets) and used to update a SysML structural model. A mission requirements model is created within the SAM, containing mission specific as well as standard GSFC mission requirements. With the linked requirements model and structural model, automated compliance checking will be performed as mission parameters evolve without the need for discipline engineers to work directly with the SAM in SysML.

MBSE↗

NASA NTRS1974

Static, stability, and dynamic analysis of shells of revolution by numerical integration - A comparison

Recent innovations in digital computer technology have enabled engineers to analyze shell structures of complex configurations without unduly restrictive approximations. An attempt is made to compare the various programs now generally available from the point of view of the advantages of the relative technique utilized, as well as the programmed state of the art. Many of the comparisons are based on the sample problems solved by the STARS-2 system of programs. These examples indicate both the structural detail which can be analyzed by, and the analytical capabilities available in, the numerical shell-of-revolution programs. All advantages and differences are demonstrated by use of solutions for realistic shell problems in the areas of statics, stability, vibrations, and dynamic response of shells subjected to time-dependent loadings.

Svalbonas, V.↗

NASA NTRS1979

Plotting shear-flow forces

Structural analysts can use computer program to study shear-flow and in-plane forces characteristic of quadrilateral panels subjected to different loading conditions. Digital outputs are presented for engineers and management, with various options to allow bulk of data to be analyzed quickly.

Furuike, T.↗

NASA NTRS1977

Life sciences Spacelab Mission Development test 3 (SMD 3) data management report

Development of a permanent data system for SMD tests was studied that would simulate all elements of the shuttle onboard, telemetry, and ground data systems that are involved with spacelab operations. The onboard data system (ODS) and the ground data system (GDS) were utilized. The air-to-ground link was simulated by a hardwired computer-to-computer interface. A patch board system was used on board to select experiment inputs, and the downlink configuration from the ODS was changed by a crew keyboard entry to support each experiment. The ODS provided a CRT display of experiment parameters to enable the crew to monitor experiment performance. An onboard analog system, with recording capability, was installed to handle high rate data and to provide a backup to the digital system. The GDS accomplished engineering unit conversion and limit sensing, and provided realtime parameter display on CRT's in the science monitoring area and the test control area.

Moseley, E. C.↗

NASA NTRS1983

Interactive Data-Collection And Display Program With Debugging

INFORM program designed to aid assembly language programers of SEL 810B computers in working with scaled-integer applications. INFORM was developed to meet needs of engineers designing real-time digital controls using SEL 810B where time and hardware constraints make use of integer arithmetic and scaled integers necessary. Package includes auxiliary routines that add dynamic data acquisition and high-speed dynamic display to INFORM capabilities.

Cwynar, D. S.↗

NASA NTRS1992

Lidar In-space Technology Experiment (LITE) Electronics Overview

The LITE electronics system consists of the following seven subsystems: Laser Transmitter Module (LTM), Boresight Assembly (BA), Aft-Optics Electronics (AOE), Digital Data Handling Unit (DDHU), Engineering Data System (EDS), Instrument Controller (IC), and the Ground Support Equipment (GSE). Each of these subsystems is discussed.

Blythe, Michael P.↗

NASA NTRS2000

Thermographic Nondestructive Evaluation of the Space Shuttle Main Engine Nozzle

The methods and results presented in this summary address the thermographic identification of interstitial leaks in the Space Shuttle Main Engine nozzles. A highly sensitive digital infrared camera is used to record the minute cooling effects associated with a leak source, such as a crack or pinhole, hidden within the nozzle wall by observing the inner "hot wall" surface as the nozzle is pressurized. These images are enhanced by digitally subtracting a thermal reference image taken before pressurization, greatly diminishing background noise. The method provides a nonintrusive way of localizing the tube that is leaking and the exact leak source position to within a very small axial distance. Many of the factors that influence the inspectability of the nozzle are addressed; including pressure rate, peak pressure, gas type, ambient temperature and surface preparation.

Walker, James L.↗

NASA NTRS2001

Thermographic/Nondestructive Evaluation of the Space Shuttle Main Engine Nozzle

The methods and results presented in this summary address the thermographic identification of interstitial leaks in the Space Shuttle Main Engine nozzles. A highly sensitive digital infrared camera is used to record the minute cooling effects associated with a leak source, such as a crack or pinhole, hidden within the nozzle wall by observing the inner 'hot wall' surface as the nozzle is pressurized. These images are enhanced by digitally subtracting a thermal reference image taken before pressurization, greatly diminishing background noise. The method provides a nonintrusive way of localizing the tube that is leaking and the exact leak source position to within a very small axial distance. Many of the factors that influence the inspectability of the nozzle are addressed; including pressure rate, peak pressure, gas type, ambient temperature and surface preparation.

Walker, J. L.↗

NASA NTRS2003

Leak Location and Classification in the Space Shuttle Main Engine Nozzle by Infrared Testing

The Space Shuttle Main Engine (SSME) is composed of cooling tubes brazed to the inside of a conical structural jacket. Because of the geometry there are regions that can't be inspected for leaks using the bubble solution and low-pressure method. The temperature change due escaping gas is detectable on the surface of the nozzle under the correct conditions. The methods and results presented in this summary address the thermographic identification of leaks in the Space Shuttle Main Engine nozzles. A highly sensitive digital infrared camera is used to record the minute temperature change associated with a leak source, such as a crack or pinhole, hidden within the nozzle wall by observing the inner "hot wall" surface as the nozzle is pressurized. These images are enhanced by digitally subtracting a thermal reference image taken before pressurization, greatly diminishing background noise. The method provides a nonintrusive way of localizing the tube that is leaking and the exact leak source position to within a very small axial distance. Many of the factors that influence the inspectability of the nozzle are addressed; including pressure rate, peak pressure, gas type, ambient temperature and surface preparation.

Russell, Samuel S.↗

NASA NTRS2003

Blind Leak Detection for Closed Systems

The current inspection technique for locating interstitial leaking in the Space Shuttle Main Engine nozzles is the application of a liquid leak check solution in the openings where the interstitials space between the tubing and the structural jacket vent out the aft end of the nozzle, while its cooling tubes are pressurized to 25 psig with Helium. When a leak is found, it is classified, and if the leak is severe enough the suspect tube is cut open so that a boroscope can be inserted to find the leak point. Since the boroscope can only cover a finite tube length and since it is impossible to identify which tube (to the right or left of the identified interstitial) is leaking, many extra and undesired repairs have been made to fix just one leak. In certain instances when the interstitials are interlinked by poor braze bonding, many interstitials will show indications of leaking from a single source. What is desired is a technique that can identify the leak source so that a single repair can be performed. Dr, Samuel Russell and James Walker, both with NASA/MSFC have developed a thermographic inspection system that addresses a single repair approach. They have teamed with Boeing/Rocketdyne to repackage the inspection processes to be suitable to address full scale Shuttle development and flight hardware and implement the process at NASA centers. The methods and results presented address the thermographic identification of interstitial leaks in the Space Shuttle Main Engine nozzles. A highly sensitive digital infrared camera (capable of detecting a delta temperature difference of 0.025 C) is used to record the cooling effects associated with a leak source, such as a crack or pinhole, hidden within the nozzle wall by observing the inner hot wall surface as the nozzle is pressurized, These images are enhanced by digitally subtracting a thermal reference image taken before pressurization. The method provides a non-intrusive way of locating the tube that is leaking and the exact leak source position to within a very small axial distance. Many of the factors that influence the inspectability of the nozzle are addressed; including pressure rate, peak pressure, gas type, ambient temperature and surface preparation. Other applications for this thermographic inspection system are the Reinforced-Carbon-Carbon (RCC) leading edge of the Space Shuttle orbiter and braze joint integrity.

Oelgoetz, Peter↗

NASA NTRS2006

Measurement Sets and Sites Commonly Used for High Spatial Resolution Image Product Characterization

Scientists within NASA's Applied Sciences Directorate have developed a well-characterized remote sensing Verification & Validation (V&V) site at the John C. Stennis Space Center (SSC). This site has enabled the in-flight characterization of satellite high spatial resolution remote sensing system products form Space Imaging IKONOS, Digital Globe QuickBird, and ORBIMAGE OrbView, as well as advanced multispectral airborne digital camera products. SSC utilizes engineered geodetic targets, edge targets, radiometric tarps, atmospheric monitoring equipment and their Instrument Validation Laboratory to characterize high spatial resolution remote sensing data products. This presentation describes the SSC characterization capabilities and techniques in the visible through near infrared spectrum and examples of calibration results.

Pagnutti, Mary↗

NASA NTRS2011

Volumetric 3D Display System with Static Screen

Current display technology has relied on flat, 2D screens that cannot truly convey the third dimension of visual information: depth. In contrast to conventional visualization that is primarily based on 2D flat screens, the volumetric 3D display possesses a true 3D display volume, and places physically each 3D voxel in displayed 3D images at the true 3D (x,y,z) spatial position. Each voxel, analogous to a pixel in a 2D image, emits light from that position to form a real 3D image in the eyes of the viewers. Such true volumetric 3D display technology provides both physiological (accommodation, convergence, binocular disparity, and motion parallax) and psychological (image size, linear perspective, shading, brightness, etc.) depth cues to human visual systems to help in the perception of 3D objects. In a volumetric 3D display, viewers can watch the displayed 3D images from a completely 360 view without using any special eyewear. The volumetric 3D display techniques may lead to a quantum leap in information display technology and can dramatically change the ways humans interact with computers, which can lead to significant improvements in the efficiency of learning and knowledge management processes. Within a block of glass, a large amount of tiny dots of voxels are created by using a recently available machining technique called laser subsurface engraving (LSE). The LSE is able to produce tiny physical crack points (as small as 0.05 mm in diameter) at any (x,y,z) location within the cube of transparent material. The crack dots, when illuminated by a light source, scatter the light around and form visible voxels within the 3D volume. The locations of these tiny voxels are strategically determined such that each can be illuminated by a light ray from a high-resolution digital mirror device (DMD) light engine. The distribution of these voxels occupies the full display volume within the static 3D glass screen. This design eliminates any moving screen seen in previous approaches, so there is no image jitter, and has an inherent parallel mechanism for 3D voxel addressing. High spatial resolution is possible with a full color display being easy to implement. The system is low-cost and low-maintenance.

Geng, Jason↗