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NASA NTRS1996

Wave Propagation in Anisotropic Composite Plates

This paper is concerned with the development of wave propagation based cost-effective ultrasonic techniques for the nondestructive materials and defects characterization in advanced structural composites. A theoretical model that captures the most significant features of wave phenomena in fiber reinforced composites is described. Laboratory tests are shown to yield results that are in excellent agreement with those obtained from the theoretical model.

nondestructive testing ultrasonic composites lamin↗

NASA NTRS1998

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

An overall goal of this research has been to enhance our understanding of the scientific principles necessary to develop advanced ultrasonic nondestructive techniques for the quantitative characterization of advanced composite structures. To this end, we have investigated a thin woven composite (5-harness biaxial weave). We have studied the effects that variations of the physical parameters of the experimental setup can have on the ultrasonic determination of the material properties for this thin composite. In particular, we have considered the variation of the nominal center frequency and the f-number of the transmitting transducer which in turn address issues such as focusing and beam spread of ultrasonic fields. This study has employed a planar, two-dimensional, receiving pseudo-array that has permitted investigation of the diffraction patterns of ultrasonic fields. Distortion of the ultrasonic field due to the spatial anisotropy of the thin composite has prompted investigation of the phenomenon of phase cancellation at the face of a finite-aperture, piezoelectric receiver. We have performed phase-sensitive and phase-insensitive analyses to provide a measure of the amount of phase cancellation at the face of a finite-aperture, piezoelectric receiver. The pursuit of robust measurements of received energy (i.e., those not susceptible to phase cancellation at the face of a finite-aperture, piezoelectric receiver) supports the development of robust techniques to determine material properties from measure ultrasonic parameters.

Miller, James G.↗

NASA NTRS1993

Material characterization and modeling with shear ography

Shearography has emerged as a useful technique for nondestructible evaluation and materials characterization of aerospace materials. A suitable candidate for the technique is to determine the response of debonds on foam-metal interfaces such as the TPS system on the External Tank. The main thrust is to develop a model which allows valid interpretation of shearographic information on TPS type systems. Confirmation of the model with shearographic data will be performed.

Workman, Gary L.↗

NASA NTRS1987

High frequency ultrasonic characterization of sintered SiC

High frequency (60 to 160 MHz) ultrasonic nondestructive evaluation was used to characterize variations in density and microstructural constituents of sintered SiC bars. Ultrasonic characterization methods included longitudinal velocity, reflection coefficient, and precise attenuation measurements. The SiC bars were tailored to provide bulk densities ranging from 90 to 98 percent of theoretical, average grain sizes ranging from 3.0 to 12.0 microns, and average pore sizes ranging from 1.5 to 4.0 microns. Velocity correlated with specimen bulk density irrespective of specimen average grain size, average pore size, and average pore orientation. Attenuation coefficient was found to be sensitive to both density and average pore size variations, but was not affected by large differences in average grain size.

Baaklini, George Y.↗

NASA NTRS1995

Ultrasonic Phased-Array Characterization for NDE Applications

Southwest Research Institute (SwRI) recently fabricated and delivered the 100-channel Ultrasonic Phased-Array Testbed System (UPATS) for NASA's Langley Research Center. NASA prepared the specifications and provided the funding to develop UPATS in order to provide a tool for the improvement of ultrasonic nondestructive evaluation (NDE) and characterization of materials. UPATS incorporates state-of-the-art phased-array concepts such as beam steering, focusing, apodization, and phase-sensitive detection which make it possible to develop more sophisticated testing methodologies. It also can be used to investigate fundamental ultrasonic propagation and detection phenomena such as refraction, diffraction, scattering, and beam broadening.

Hanley, John J.↗

NASA NTRS1982

Advances in nondestructive evaluation technology

Research at NASA Langley's Materials Characterization Instrumentation Section has followed the philosophy of improving the science base of nondestructive evaluation and advancing the state of the art of quantitative interpretability of physical measurements of materials. Details of several R&D programs choosen to highlight the last several years are given. Applications of these technologies are presented in the area of stress measurement, characterization of metal heat treatment, and evaluation of material internal structure. A second focus of the program is on quantitative transducers/measurements that have resulted in better data in irregular inhomogeneous materials such as composites. Examples are presented of new capabilities resulting from these advances that include fatigue and impact damage evaluation.

Joseph S. Heyman↗

NASA NTRS2016

Composite Characterization Using Ultrasonic Wavefield Techniques

The large-scale use of composite components in aerospace applications is expected to continue due to the benefits of composite materials, such as reduced weight, increased strength, and tailorability. NASA's Advanced Composites Project (ACP) has the goals of reducing the timeline for certification of composite materials and enabling the expanded use of advanced composite materials. A key technical challenge area for accomplishing these goals is the need for nondestructive evaluation and materials characterization techniques that are optimized for rapid inspection and detailed defect/damage characterization in composite materials. This presentation will discuss ongoing research investigating the use of ultrasonic wavefield techniques for the characterization of defects such as fiber waviness and delamination damage. Ongoing work includes the development of realistic ultrasonic simulation tools for use in predicting the inspectability of composites and optimizing inspection methodologies. Recent studies on detecting/characterizing delamination damage and fiber waviness via wavefield methods will be described.

Leckey, Cara A. C.↗

NASA NTRS2015

Ultrasonic Characterization of Aerospace Composites

Composite materials have seen an increased use in aerospace in recent years and it is expected that this trend will continue due to the benefits of reduced weight, increased strength, and other factors. Ongoing work at NASA involves the investigation of the large-scale use of composites for spacecraft structures (SLS components, Orion Composite Crew Module, etc). NASA is also involved in work to enable the use of composites in advanced aircraft structures through the Advanced Composites Project (ACP). In both areas (space and aeronautics) there is a need for new nondestructive evaluation and materials characterization techniques that are appropriate for characterizing composite materials. This paper will present an overview of NASA's needs for characterizing aerospace composites, including a description of planned and ongoing work under ACP for the detection of composite defects such as fiber waviness, reduced bond strength, delamination damage, and microcracking. The research approaches include investigation of angle array, guided wave, and phase sensitive ultrasonic methods. The use of ultrasonic simulation tools for optimizing and developing methods will also be discussed.

Leckey, Cara↗

NASA NTRS1989

High-frequency ultrasonic characterization of sintered silicon carbide

High-frequency 60- to 160-MHz ultrasonic nondestructive evaluation was used to characterize variations in density and microstructural constituents of sintered SiC bars. Ultrasonic characterization methods included longitudinal velocity, reflection coefficient, and precise attenuation measurements. The SiC bars were tailored to provide bulk densities ranging from 90 to 98 percent of theoretical, average grain sizes ranging from 3.0 to 12.0 microns, and average pore sizes ranging from 1.5 to 4.0 microns. Velocity correlated with specimen bulk density irrespective of specimen average grain size, average pore size, and average pore orientation. The attenuation coefficient was found to be sensitive to both density and average pore size variations, but was not affected by large differences in average grain size.

Baaklini, George Y.↗

NASA NTRS1988

Nondestructive evaluation of advanced ceramics

A review is presented of Lewis Research Center efforts to develop nondestructive evaluation techniques for characterizing advanced ceramic materials. Various approaches involved the use of analytical ultrasonics to characterize monolythic ceramic microstructures, acousto-ultrasonics for characterizing ceramic matrix composites, damage monitoring in impact specimens by microfocus X-ray radiography and scanning ultrasonics, and high resolution computed X-ray tomography to identify structural features in fiber reinforced ceramics.

Klima, Stanley J.↗

DOE OSTI2023

Development of an advanced ultrasonic phased array for the characterization of thick, reinforced concrete components (Final Scientific/Technical Report)

There are no nondestructive evaluation (NDE) tools capable of characterizing microscale damage throughout the thickness of concrete components, due to the multiphase, heterogeneous and multiscale nature of concrete. Ultrasound is only scattered by features at the same length scale, or smaller, than the wavelength of a wave’s dominant frequency. Successful imaging of microscale damage using ultrasound requires that the ultrasonic wavelength be on the order of a few millimeters (or smaller), yet the heterogeneous microstructure of concrete, with its fine and coarse aggregates, is on this same (and higher) micrometer/millimeter length scale, causing excessive ultrasonic wave scattering even in “good” concrete. The proposed solution applies non-collinear wave mixing to spatially image microscale damage, while still maintaining penetration through thick concrete components. This microscale imaging is possible by combining nonlinear wave mixing, with advanced phased array hardware and software to develop a breakthrough tool that will bring revolutionary changes in NDE of concrete infrastructure in terms of image resolution and depth of penetration. This work uses non-collinear wave mixing which exploits the physics that material nonlinearities such as microscale damage, cause interactions between two intersecting ultrasonic waves due to cross-mixing, which can lead to the generation of a third wave with a frequency and wave number of the sum or difference of the incident waves. The concrete material volume at this mixing point is characterized/imaged. This project delivered a single-sided nonlinear ultrasonic phased array imaging device, that can image microscale damage (microcracks of 100 micrometers) through a 0.5 m thick concrete component and assessed the commercial feasibility of such arrays for improved crack detection.

42 ENGINEERING↗

DOE OSTI2024

Materials Characterization, Prediction, and Control Project: Characterization of 316L Stainless Steel after Solid Phase Processing using Ultrasonic NDE Method

The Pacific Northwest National Laboratory undertook the Materials Characterization, Prediction, and Control Laboratory Directed Research and Development Project to advance understanding of nuclear material processing and enable multifold acceleration in the development and qualification of new material systems produced via advanced manufacturing methods, such as solid phase processing, for use in national security and advanced energy applications (Smith 2021). A motivation of the Materials Characterization, Prediction, and Control Project was to demonstrate ultrasonic testing as a nondestructive evaluation method to complement traditional destructive methods for characterizing material microstructure with emphasis on grain size determination using a method that may have future applications for real-time inline process monitoring. The objective of the work described in this report is to establish the process and an analysis method for measuring grain sizes of polycrystalline metals with ultrafine grains using ultrasonic shear wave backscattering, building on prior studies on coarser-grained material. The work involves five tasks: Measured ultrasonic backscattering experimentally for a series of 316L stainless steel specimens with various grain sizes made by friction stir processing. Calculated ultrasonic backscattering coefficients from experimental data based on a physical measurement model. Measured ground truth grain sizes of the specimens from electron backscatter diffraction grain boundary images using a generalization of the ASTM E112 (ASTM 2021) intercept method. Built a curve of ultrasonic backscattering coefficients versus the ground truth intercept-based grain sizes to determine the correlation between mean grain sizes and ultrasonic measurements. Demonstrated the ability of using the correlation curve to deduce grain sizes with measured ultrasonic backscattering coefficients for a few 316L stainless steel specimens whose grain sizes were unknown beforehand but were targeted to be an extrapolation to larger grain sizes than used to formulate the correlation curves. Experimental procedures and computational algorithms are developed and validated for these tasks. This work establishes an ultrasonic technique for characterizing material microstructure with ultrafine grains that are often resulted by solid-phase processing. The technique is nondestructive, and it has the potential to be used for real time inline process monitoring. This work successfully demonstrates the viability of an ultrasonic nondestructive evaluation method for microstructural characterization of material having ultrafine grain structure (as small as 1?mm) and produced by an advanced manufacturing method. This includes a demonstration of the method to extrapolate to other conditions. While not demonstrated here, the method is expected to be viable for in-line, or near-inline, process monitoring in advanced manufacturing applications with suitable consideration for access of instrumentation to the material being manufactured.

316 L Stainless Steel↗

DOE OSTI2022

Nondestructive Evaluation of Stress Corrosion Cracking in a Welded Steel Plate Using Guided Ultrasonic Waves

Stress corrosion cracking (SCC) had occurred in early-generation high-level nuclear waste tanks constructed by welding carbon steel. This paper describes an ultrasonic inspection system and its fundamental ability to detect and quantify the length of SCC on thick welded steel plates. The finite element method (FEM) was applied to simulate the welding process to estimate the welding residual stress field. Growth of stress corrosion cracks is driven by crack stress intensities exceeding the subcritical cracking threshold intensity. The subject plate was experimentally inspected with ultrasonic nondestructive evaluation (NDE) techniques to characterize the extent of SCC. The NDE system uses a piezoelectric transducer to generate guided waves in the thick steel plate, and a scanning laser Doppler vibrometer (SLDV) to measure multidimensional time–space wavefield data over a user-defined scanning area in the plate surface. The measured wavefield data can show wave interactions in a localized area in the plate due to the presence of the discontinuities of the SCC. To generate an inspection image that can precisely show the crack’s location and/or the dimension, the wavefield data are further processed to generate inspection image that maps the entire sample plate so the crack can be clearly identified in the plate while its length can be readily estimated. In conclusion, the ultrasonic test results for crack length agree well with the visually estimated length and are close to that predicted by the FEM for cracks in the weld residual stress field.

36 MATERIALS SCIENCE↗

NASA NTRS1982

Interrelation of material microstructure, ultrasonic factors, and fracture toughness of two phase titanium alloy

The pivotal role of an alpha-beta phase microstructure in governing fracture toughness in a titanium alloy, Ti-662, is demonstrated. The interrelation of microstructure and fracture toughness is demonstrated using ultrasonic measurement techniques originally developed for nondestructive evaluation and material property characterization. It is shown that the findings determined from ultrasonic measurements agree with conclusions based on metallurgical, metallographic, and fractographic observations concerning the importance of alpha-beta morphology in controlling fracture toughness in two phase titanium alloys.

Vary, A.↗

NASA NTRS1995

Study Of Nondestructive Techniques For Testing Composites

Study evaluates some nondestructive methods for characterizing ceramic-, metal-, and polymer-matrix composite materials. Results demonstrated utility of two ultrasonic methods for obtaining quantitative data on microstructural anomalies in composite materials.

Roth, D.↗

NASA NTRS2002

Ultrasonic Resonance Spectroscopy of Composite Rims for Flywheel Rotors

Flywheel energy storage devices comprising multilayered composite rotor systems are being studied extensively for utilization in the International Space Station. These composite material systems were investigated with a recently developed ultrasonic resonance spectroscopy technique. The ultrasonic system employs a continuous swept-sine waveform and performs a fast Fourier transform (FFT) on the frequency response spectrum. In addition, the system is capable of equalizing the amount of energy at each frequency. Equalization of the frequency spectrum, along with interpretation of the second FFT, aids in the evaluation of the fundamental frequency. The frequency responses from multilayered material samples, with and without known defects, were analyzed to assess the capabilities and limitations of this nondestructive evaluation technique for material characterization and defect detection. Amplitude and frequency changes were studied from ultrasonic responses of thick composite rings and a multiring composite rim. A composite ring varying in thickness was evaluated to investigate the full thickness resonance. The frequency response characteristics from naturally occurring voids in a composite ring were investigated. Ultrasonic responses were compared from regions with and without machined voids in a composite ring and a multiring composite rim. Finally, ultrasonic responses from the multiring composite rim were compared before and after proof spin testing to 63,000 rpm.

Harmon, Laura M.↗

NASA NTRS2004

Automated Guided-Wave Scanning Developed to Characterize Materials and Detect Defects

The Nondestructive Evaluation (NDE) Group of the Optical Instrumentation Technology Branch at the NASA Glenn Research Center has developed a scanning system that uses guided waves to characterize materials and detect defects. The technique uses two ultrasonic transducers to interrogate the condition of a material. The sending transducer introduces an ultrasonic pulse at a point on the surface of the specimen, and the receiving transducer detects the signal after it has passed through the material. The aim of the method is to correlate certain parameters in both the time and frequency domains of the detected waveform to characteristics of the material between the two transducers. The scanning system is shown. The waveform parameters of interest include the attenuation due to internal damping, waveform shape parameters, and frequency shifts due to material changes. For the most part, guided waves are used to gauge the damage state and defect growth of materials subjected to various mechanical or environmental loads. The technique has been applied to polymer matrix composites, ceramic matrix composites, and metal matrix composites as well as metallic alloys. Historically, guided wave analysis has been a point-by-point, manual technique with waveforms collected at discrete locations and postprocessed. Data collection and analysis of this type limits the amount of detail that can be obtained. Also, the manual movement of the sensors is prone to user error and is time consuming. The development of an automated guided-wave scanning system has allowed the method to be applied to a wide variety of materials in a consistent, repeatable manner. Experimental studies have been conducted to determine the repeatability of the system as well as compare the results obtained using more traditional NDE methods. The following screen capture shows guided-wave scan results for a ceramic matrix composite plate, including images for each of nine calculated parameters. The system can display up to 18 different wave parameters. Multiple scans of the test specimen demonstrated excellent repeatability in the measurement of all the guided-wave parameters, far exceeding the traditional point-by-point technique. In addition, the scan was able to detect a subsurface defect that was confirmed using flash thermography This technology is being further refined to provide a more robust and efficient software environment. Future hardware upgrades will allow for multiple receiving transducers and the ability to scan more complex surfaces. This work supports composite materials development and testing under the Ultra-Efficient Engine Technology (UEET) Project, but it also will be applied to other material systems under development for a wide range of applications.

Martin, Richard E.↗

NASA NTRS1990

Advanced NDE techniques for quantitative characterization of aircraft

Recent advances in nondestructive evaluation (NDE) at NASA Langley Research Center and their applications that have resulted in quantitative assessment of material properties based on thermal and ultrasonic measurements are reviewed. Specific applications include ultrasonic determination of bolt tension, ultrasonic and thermal characterization of bonded layered structures, characterization of composite materials, and disbonds in aircraft skins.

Heyman, Joseph S.↗