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Quantitative nondestructive evaluation: Requirements for tomorrow's reliability

Quantitative Nondestructive Evaluation (QNDE) is the technology of measurement, analysis, and prediction of the state of material/structural systems for safety, reliability, and mission assurance. QNDE has impact on everyday life from the cars we drive, the planes we fly, the buildings we work or live in, literally to the infrastructure of our world. Here, researchers highlight some of the new sciences and technologies that are part of a safer, cost effective tomorrow. Specific technologies that are discussed are thermal QNDE of aircraft structural integrity, ultrasonic QNDE for materials characterization, and technology spinoffs from aerospace to the medical sector. In each case, examples are given of how new requirements result in enabling measurement technologies, which in turn change the boundaries of design/practice.

Heyman, Joseph S.

Overview of space propulsion systems for identifying nondestructive evaluation and health monitoring opportunities

The next generation of space propulsion systems will be designed to incorporate advanced health monitoring and nondestructive inspection capabilities. As a guide to help the nondestructive evaluation (NDE) community impact the development of these space propulsion systems, several questions should be addressed. An overview of background and current information on space propulsion systems at both the programmatic and technical levels is provided. A framework is given that will assist the NDE community in addressing key questions raised during the 2 to 5 April 1990 meeting of the Joint Army-Navy-NASA-Air Force (JANNAF) Nondestructive Evaluation Subcommittee (NDES).

Generazio, Edward R.

Proceedings of the First Annual Symposium for Nondestructive Evaluation of Bond Strength

Quantitative adhesive bond strength measurement has been an issue for over thirty years. Utilization of nonlinear ultrasonic nondestructive evaluation methods has shown more effectiveness than linear methods on adhesive bond analysis, resulting in an increased sensitivity to changes in bondline conditions. Correlation to changes in higher order material properties due to microstructural changes using nonlinear ultrasonics has been shown and could relate to bond strength. Nonlinear ultrasonic energy is an order of magnitude more sensitive than linear ultrasound to these material parameter changes and to acoustic velocity changes caused by the acoustoelastic effect when a bond is prestressed. This increased sensitivity will assist in getting closer to quantitative measurement of adhesive bond strength. Signal correlations between non-linear ultrasonic measurements and initialization of bond failures have been successfully measured. This paper reviews nonlinear bond strength research efforts presented by university and industry experts at the First Annual Symposium for Nondestructive Evaluation of Bond Strength organized by the NDE Sciences Branch at NASA Langley in November 1997.

Roberts, Mark J.

Nondestructive evaluation of composite materials - A design philosophy

Efficient and reliable structural design utilizing fiber reinforced composite materials may only be accomplished if the materials used may be nondestructively evaluated. There are two major reasons for this requirement: (1) composite materials are formed at the time the structure is fabricated and (2) at practical strain levels damage, changes in the condition of the material, that influence the structure's mechanical performance is present. The fundamental basis of such a nondestructive evaluation capability is presented. A discussion of means of assessing nondestructively the material condition as well as a damage mechanics theory that interprets the material condition in terms of its influence on the mechanical response, stiffness, strength and life is provided.

Duke, J. C., Jr.

Acousto-ultrasonic nondestructive evaluation of materials using laser beam generation and detection

The acousto-ultrasonic method has proven to be a most interesting technique for nondestructive evaluation of the mechanical properties of a variety of materials. Use of the technique or a modification thereof, has led to correlation of the associated stress wave factor with mechanical properties of both metals and composite materials. The method is applied to the nondestructive evaluation of selected fiber reinforced structural composites. For the first time, conventional piezoelectric transducers were replaced with laser beam ultrasonic generators and detectors. This modification permitted true non-contact acousto-ultrasonic measurements to be made, which yielded new information about the basic mechanisms involved as well as proved the feasibility of making such non-contact measurements on terrestrial and space structures and heat engine components. A state-of-the-art laser based acousto-ultrasonic system, incorporating a compact pulsed laser and a fiber-optic heterodyne interferometer, was delivered to the NASA Lewis Research Center.

Huber, Robert D.

Nondestructive evaluation technique guide

A total of 70 individual nondestructive evaluation (NDE) techniques are described. Information is presented that permits ease of comparison of the merits and limitations of each technique with respect to various NDE problems. An NDE technique classification system is presented. It is based on the system that was adopted by the National Materials Advisory Board (NMAB). The classification system presented follows the NMAB system closely with the exception of additional categories that have been added to cover more advanced techniques presently in use. The rationale of the technique is explained. The format provides for a concise description of each technique, the physical principles involved, objectives of interrogation, example applications, limitations of each technique, a schematic illustration, and key reference material. Cross-index tabulations are also provided so that particular NDE problems can be referred to appropriate techniques.

Vary, A.

Nondestructive evaluation

Technological survey summarizes accumulated knowledge of nondestructive-evaluation (NDE) testing methodology application and reliability as it is presented in literature covering time period from 1962 to 1975.

Mandel, G.

Guidebook for Assessing Similarity and Implementing Empirical Transfer Functions for Probability of Detection (POD) Demonstrations for Signal Based Nondestructive Evaluation (NDE) Methods

This document provides guidance for assessing similarity relative to nondestructive evaluation (NDE) detectability based on Probability of Detection demonstrations when comparing different NDE inspection situations. Differences in inspection situations addressed by the similarity assessment methodology herein can include differences in the component being inspected, and differences in the conditions for the inspection. Additional differences in the inspection situation relative to differences in the method or procedure are not addressed in this document but can be assessed using NDE calibration or instrument standardization specimens.

Probability of Detection

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.

Proceedings of the Second Annual Symposium for Nondestructive Evaluation of Bond Strength

Ultrasonics, microwaves, optically stimulated electron emission (OSEE), and computational chemistry approaches have shown relevance to bond strength determination. Nonlinear ultrasonic nondestructive evaluation methods, however, have shown the most effectiveness over other methods on adhesive bond analysis. Correlation to changes in higher order material properties due to microstructural changes using nonlinear ultrasonics has been shown related to bond strength. Nonlinear ultrasonic energy is an order of magnitude more sensitive than linear ultrasound to these material parameter changes and to acoustic velocity changes caused by the acoustoelastic effect when a bond is prestressed. Signal correlations between non-linear ultrasonic measurements and initialization of bond failures have been measured. This paper reviews bond strength research efforts presented by university and industry experts at the Second Annual Symposium for Nondestructive Evaluation of Bond Strength organized by the NDE Sciences Branch at NASA Langley in November 1998.

Roberts, Mark J.

Physical interpretation and development of ultrasonic nondestructive evaluation techniques applied to the quantitative characterization of textile composite materials

In this Progress Report, we describe our continuing research activities concerning the development and implementation of advanced ultrasonic nondestructive evaluation methods applied to the inspection and characterization of complex composite structures. We explore the feasibility of implementing medical linear array imaging technology as a viable ultrasonic-based nondestructive evaluation method to inspect and characterize complex materials. As an initial step toward the application of linear array imaging technology to the interrogation of a wide range of complex composite structures, we present images obtained using an unmodified medical ultrasonic imaging system of two epoxy-bonded aluminum plate specimens, each with intentionally disbonded regions. These images are compared with corresponding conventional ultrasonic contact transducer measurements in order to assess whether these images can detect disbonded regions and provide information regarding the nature of the disbonded region. We present a description of a standoff/delay fixture which has been designed, constructed, and implemented on a Hewlett-Packard SONOS 1500 medical imaging system. This standoff/delay fixture, when attached to a 7.5 MHz linear array probe, greatly enhances our ability to interrogate flat plate specimens. The final section of this Progress Report describes a woven composite plate specimen that has been specially machined to include intentional flaws. This woven composite specimen will allow us to assess the feasibility of applying linear array imaging technology to the inspection and characterization of complex textile composite materials. We anticipate the results of this on-going investigation may provide a step toward the development of a rapid, real-time, and portable method of ultrasonic inspection and characterization based on linear array technology.

Miller, James G.

Application of Raman Spectroscopy for Nondestructive Evaluation of Composite Materials

This paper will present an overview of efforts to investigate the application of Raman spectroscopy for the characterization of Kevlar materials. Raman spectroscopy is a laser technique that is sensitive to molecular interactions in materials such as Kevlar, graphite and carbon used in composite materials. The overall goal of this research reported here is to evaluate Raman spectroscopy as a potential nondestructive evaluation (NDE) tool for the detection of stress rupture in Kevlar composite over-wrapped pressure vessels (COPVs). Characterization of the Raman spectra of Kevlar yarn and strands will be presented and compared with analytical models provided in the literature. Results of testing to investigate the effects of creep and high-temperature aging on the Raman spectra will be presented.

Washer, Glenn A.

Physical interpretation and development of ultrasonic nondestructive evaluation techniques applied to the quantitative characterization of textile composite materials

In this Progress Report, we describe our current research activities concerning the development and implementation of advanced ultrasonic nondestructive evaluation methods applied to the characterization of stitched composite materials and bonded aluminum plate specimens. One purpose of this investigation is to identify and characterize specific features of polar backscatter interrogation which enhance the ability of ultrasound to detect flaws in a stitched composite laminate. Another focus is to explore the feasibility of implementing medical linear array imaging technology as a viable ultrasonic-based nondestructive evaluation method to inspect and characterize bonded aluminum lap joints. As an approach to implementing quantitative ultrasonic inspection methods to both of these materials, we focus on the physics that underlies the detection of flaws in such materials.

Miller, James G.

Summary of the nondestructive evaluation session

Advanced material systems and designs require improved nondestructive evaluation (NDE) techniques for quality control, failure analysis and properties monitoring. Some advanced NDE techniques such as infrared scanning systems, laser holographic applications and the use of the Mossbauer effect are outlined. Applications of these techniques are discussed for evaluating the new space shuttle external insulation materials, aircraft structures and engine components, and precursors to crack initiation and growth.

Stinebring, R. C.

Large Area Nondestructive Evaluation of a Fatigue Loaded Composite Structure

Large area nondestructive evaluation (NDE) inspections are required for fatigue testing of composite structures to track damage initiation and growth. Of particular interest is the progression of damage leading to ultimate failure to validate damage progression models. In this work, passive thermography and acoustic emission NDE were used to track damage growth up to failure of a composite three-stringer panel. Fourteen acoustic emission sensors were placed on the composite panel. The signals from the array were acquired simultaneously and allowed for acoustic emission location. In addition, real time thermal data of the composite structure were acquired during loading. Details are presented on the mapping of the acoustic emission locations directly onto the thermal imagery to confirm areas of damage growth leading to ultimate failure. This required synchronizing the acoustic emission and thermal data with the applied loading. In addition, processing of the thermal imagery which included contrast enhancement, removal of optical barrel distortion and correction of angular rotation before mapping the acoustic event locations are discussed.

Joseph N Zalameda

Guidebook of nondestructive evaluation techniques for materials and structures

Seventy nondestructive techniques for evaluating material and structures are described in guidebook. Standardized format facilitates comparison of their merits and limitations for solving various problems. Guide includes index of flaw types and tabulated guide to use of nondestructive evaluation techniques. Alternative technique names are cross-referenced.

Vary, A.

Nondestructive Evaluation of Adhesively Bonded Joints

The final report consists of 5 published papers in referred journals and a technical letter to the technical monitor. These papers include the following: (1) Comparison of the effects of debonds and voids in adhesive; (2) On the peak shear stresses in adhesive joints with voids; (3) Nondestructive evaluation of adhesively bonded joints by acousto-ultrasonic technique and acoustic emission; (4) Multiaxial fatigue life evaluation of tubular adhesively bonded joints; (5) Theoretical and experimental evaluation of the bond strength under peeling loads. The letter outlines the progress of the research. Also included is preliminary information on the study of nondestructive evaluation of composite materials subjected to localized heat damage. The investigators studied the effects of localized heat on unidirectional fiber glass epoxy composite panels. Specimens of the fiber glass epoxy composites were subjected to 400 C heat for varying lengths of time. The specimens were subjected to nondestructive tests. The specimens were then pulled to their failure and acoustic emission of these specimens were measured. The analysis of the data was continuing as of the writing of the letter, and includes a finite element stress analysis of the problem.

Nayeb-Hashemi, Hamid

A Survey of NASA Standard Nondestructive Evaluation (NDE)

This document provides a comprehensive review to trace the evolution of NASA’s Standard nondestructive evaluation (NDE) flaw sizes provided in NASA-STD-5009B for fracture-critical metallic spaceflight hardware. A NASA Standard NDE flaw size is considered to be conservative such that most inspectors, trained and certified in the specific method, are expected to provide the required 90/95 probability of detection (POD) for that flaw size. As such, individual certified inspectors are not required to perform POD demonstration testing to be allowed to inspect fracture-critical hardware for that specific method.

Probability of Detection