Search NASA⌕ Search

SEARCH · Search NASA

Results for “defects metrics”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2

Assessment of Segmentation-Induced Deviations of Porosity Metrics in Powder Bed Fusion Additively Manufactured Components

Post processing X-ray computational tomography (CT) inspection data for additively manufactured (AM) components can induce deviations in defect quantification, affecting subsequent fatigue and failure predictions. To assess the influence and potential impact of segmentation-induced measurement deviations, this paper applies several segmentation techniques to X-ray CT data for powder bed fusion Ti-6Al-4V specimens exhibiting porosity conditions. X-ray CT reconstructions were segmented with varying techniques including Otsu’s thresholding, random forest, k-nearest neighbors, and the multilayer perceptron. Metrics such as pore size and global porosity were compared for internal validity. Then, top-down X-ray CT measurements of surface-breaking porosity were compared to optical profilometry for cross-validation.

Data fusion↗

Design for Inspection: A Formalized Approach to Evaluating the Inspectability of Aerospace Structures Early in the Design Process

NDE engineers are often confronted with structural design choices that present challenges to meeting inspection requirements. These challenges at best increase the resources needed to design an inspection solution and, at worst, require resource intensive redesign of the structure. If the inspectability of structure can be determined early in the design cycle, these challenging inspection scenarios can be avoided. Therefore, there exists a need for a resource friendly formalized approach to gauge the inspectability of a structure. This paper proposes the use of a novel inspectability metric to meet this need. The inspectability metric is a standardized, automation friendly procedure that uses simulations to determine inspectability. It provides a suite of simulation tests to interrogate the ability to find defects and the sensitivity to variability. The testing rubric is designed to maximize the coverage of the parameter space while minimizing the number of simulations needed. In this preliminary study, we will demonstrate how the inspectability metric is able to determine the inspectability of a structure as a function of changes in the structure’s design.

Peter Juarez↗

A Novel Additive Manufacturing Process Metric for Predicting Spatter-related Porosity in Laser Powder Bed Fusion

Components fabricated using the powder bed fusion laser beam metallic (PBF) additive manufacturing (AM) process comprise a multitude of sequential weld passes. Porosity defects resulting from weld pass inconsistencies are a concern for PBF materials and have a strong adverse effect on the mechanical properties. In an effort to understand and avoid spatter induced porosity, this work aims to provide a novel computational technique that can be used to quantify and predict the sequence-sensitive impact of spatter upon the PBF process stability and consequential porosity in as-printed material. A novel spatter impact AM model-based process metric (AM-PM) is introduced to model and quantify the impact that spatter has on the PBF process. The occurrence of spatter induced porosity is studied using thermal rise, lack of fusion, and spatter impact AM-PMs synchronized with porosity measured by high-resolution X-ray computed tomography. Six cylindrical specimens were designed to compare the AM-PM correlations with porosity across two different laser powers and three hatch scanning strategies. A point field based computational approach is shown to be effective for testing the influence of the different AM-PMs and interrogating the physical process conditions underlying the porosity formation. Further, characterization using optical metallography and scanning electron microscopy indicated that both keyhole and lack of fusion porosity correlated with the spatter impact AM-PM, which can be exploited to predict and control spatter related porosity by the hatch strategy. Efforts to predict porosity composition within PBF material should incorporate the PBF process disturbances that can result from spatter. The spatter impact AM-PM can be readily incorporated into the development of defect prediction models at the part scale.

Additive Manufacturing↗

Full Life-Cycle Defect Management Assessment: Initial Inspection Data Collection Results and Research Questions for Further Study

It is often the case in software projects that when schedule and budget resources are limited, the Verification and Validation (V&V) activities suffer. Fewer V&V activities can be afforded and moreover, short-term challenges can result in V&V activities being scaled back or dropped altogether. As a result, too often the default solution is to save activities for improving software quality until too late in the life-cycle, relying on late-term code inspections followed by thorough testing activities to reduce defect counts to acceptable levels. As many project managers realize, however, this is a resource-intensive way of achieving the required quality for software. The Full Life-cycle Defect Management Assessment Initiative, funded by NASA s Office of Safety and Mission Assurance under the Software Assurance Research Program, aims to address these problems by: Improving the effectiveness of early life-cycle V&V activities to make their benefits more attractive to team leads. Specifically, we focus on software inspection, a proven method that can be applied to any software work product, long before executable code has been developed; Better communicating this effectiveness to software development teams, along with suggestions for parameters to improve in the future to increase effectiveness; Analyzing the impact of early life-cycle V&V on the effectiveness and cost required for late life-cycle V&V activities, such as testing, in order to make the tradeoffs more apparent. This white paper reports on an initial milestone in this work, the development of a preliminary model of inspection effectiveness across multiple NASA Centers. This model contributes toward reaching our project goals by: Allowing an examination of inspection parameters, across different types of projects and different work products, for an analysis of factors that impact defect detection effectiveness. Allowing a comparison of this NASA-specific model to existing recommendations in the literature regarding how to plan effective inspections. Forming a baseline model which can be extended to incorporate factors describing: the numbers and types of defects that are missed by inspections; how such defects flow downstream through software development phases; how effectively they can be caught by testing activities in the late stages of development. The model has been implemented in a prototype web-enabled decision-support tool which allows developers to enter their inspection data and receive feedback based on a comparison against the model. The tool also allows users to access reusable materials (such as checklists) from projects included in the baseline. Both the tool itself and the model underlying it will continue to be extended throughout the remainder of this initiative. As results of analyzing inspection effectiveness for defect containment are determined, they can be shared via the tool and also via updates to existing training courses on metrics and software inspections. Moreover, the tool will help satisfy key CMMI requirements for the NASA Centers, as it will enable NASA to take a global view across peer review results for various types of projects to identify systemic problems. This analysis can result in continuous improvements to the approach to verification.

Shull, Forrest↗

Shuttle Wing Leading Edge Root Cause NDE Team Findings and Implementation of Quantitative Flash Infrared Thermography

Comparison metrics can be established to reliably and repeatedly establish the health of the joggle region of the Orbiter Wing Leading Edge reinforced carbon carbon (RCC) panels. Using these metrics can greatly reduced the man hours needed to perform, wing leading edge scanning for service induced damage. These time savings have allowed for more thorough inspections to be preformed in the necessary areas with out affecting orbiter flow schedule. Using specialized local inspections allows for a larger margin of safety by allowing for more complete characterizations of panel defects. The presence of the t-seal during thermographic inspection can have adverse masking affects on ability properly characterize defects that exist in the joggle region of the RCC panels. This masking affect dictates the final specialized inspection should be preformed with the t-seal removed. Removal of the t-seal and use of the higher magnification optics has lead to the most effective and repeatable inspection method for characterizing and tracking defects in the wing leading edge. Through this study some inadequacies in the main health monitoring system for the orbiter wing leading edge have been identified and corrected. The use of metrics and local specialized inspection have lead to a greatly increased reliability and repeatable inspection of the shuttle wing leading edge.

Burke, Eric R.↗

Correlations of Additive Manufacturing Model-Based Process Metrics With Spatter-Induced Porosity in the Powder Bed Fusion-Laser Beam/Metallic Process

Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M) additive manufacturing (AM) process comprise a multitude of sequential weld passes. Qualifying materials for components in critical applications requires a thorough understanding of pertinent processing-microstructure-property relationships. Porosity defects have a strong adverse effect on the mechanical properties of a material. The morphology of porosity defects created by lack of fusion in PBF-LB/M often exhibit high aspect ratios that can act as stress concentrators and become crack initiation sites. The occurrence of spatter induced porosity is studied using synchronized AM model-based process metrics and porosity measured by high-resolution X-ray computed tomography. A novel AM process metric is introduced to quantify the relative exposure to spatter ejecta impacts and incorporation throughout the sequence of the PBF-LB/M process. Further characterization using optical metallography and scanning electron microscopy indicated that both keyhole and lack of fusion porosity correlated statistically with the spatter ejecta impact field of the PBF-LB/M process. Both keyhole and lack of fusion porosity can be predicted by the spatter exposure process metric, which can be exploited to control the fusion sequence.

Additive Manufacturing↗

Correlations Between Porosity, Spatter, and Process Metrics for Powder Bed Fusion Laser Beam Metallic Additive Manufacturing

Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M)additive manufacturing process are the result of a multitude of weld passes conducted sequentially. Qualifying components for aerospace applications requires a thorough understanding of the process-structure-properties relationships. Porosity defects are known to have a strong adverse effect on the mechanical properties of a component. In particular, porosity defects created by lack of fusion have high aspect ratio morphologies leading to stress concentrations that become crack initiation sites. In the present work, the occurrence of spatter induced lack of fusion porosity was studied using synchronized in-situ process monitoring, additive manufacturing model-based process metrics, and high-resolution X-ray computed tomography. The results show that lack of fusion porosity is statistically correlated with unremoved welding spatter ejecta of the PBF-LB/M process and process metrics related to the hatching strategy.

Qualification↗

Integration of Design Data Into Automated Fiber Placement Process Planning Metrics

With the ever-expanding aviation industry, a need is arising for more rapid production of composite aircraft to meet increasing demand. State-of-the-art aircraft such as the Boeing 787showcase 50% composite material usage by weight, highlighting this emerging industry-wide adoption of the material system. Currently, many of the large structures associated with these aircraft are manufactured additively via Automated Fiber Placement (AFP). The AFP process shows great potential for efficient manufacturing, however unavoidable defects still occur because of tool surface geometry, placement errors, or poor process planning, resulting in decreased quality and throughput. Due to such effects, it is critical to incorporate design for manufacturing (DFM) principles to achieve the optimal manufacturing plan and resulting structure. This work will develop a methodology for incorporating design information into process planning metrics in an automated fashion to achieve an optimal set of process inputs.The analysis incorporates HyperX, Computer Aided Process Planning (CAPP) and Vericut Composite Programming (VCP). Safety margins from HyperX are imported into CAPP where AFP defects are mapped to the values. The resulting margins are then incorporated into the CAPP manufacturability algorithms, creating a design informed process planning analysis

Automated Fiber Placement↗

Toward Intelligent Software Defect Detection

Source code level software defect detection has gone from state of the art to a software engineering best practice. Automated code analysis tools streamline many of the aspects of formal code inspections but have the drawback of being difficult to construct and either prone to false positives or severely limited in the set of defects that can be detected. Machine learning technology provides the promise of learning software defects by example, easing construction of detectors and broadening the range of defects that can be found. Pinpointing software defects with the same level of granularity as prominent source code analysis tools distinguishes this research from past efforts, which focused on analyzing software engineering metrics data with granularity limited to that of a particular function rather than a line of code.

Benson, Markland J.↗

The development and application of composite complexity models and a relative complexity metric in a software maintenance environment

A great deal of effort is now being devoted to the study, analysis, prediction, and minimization of software maintenance expected cost, long before software is delivered to users or customers. It has been estimated that, on the average, the effort spent on software maintenance is as costly as the effort spent on all other software costs. Software design methods should be the starting point to aid in alleviating the problems of software maintenance complexity and high costs. Two aspects of maintenance deserve attention: (1) protocols for locating and rectifying defects, and for ensuring that noe new defects are introduced in the development phase of the software process; and (2) protocols for modification, enhancement, and upgrading. This article focuses primarily on the second aspect, the development of protocols to help increase the quality and reduce the costs associated with modifications, enhancements, and upgrades of existing software. This study developed parsimonious models and a relative complexity metric for complexity measurement of software that were used to rank the modules in the system relative to one another. Some success was achieved in using the models and the relative metric to identify maintenance-prone modules.

Hops, J. M.↗

Terrestrial Sources of X-Ray Radiation and Their Effects on NASA Flight Hardware

X-rays are an energetic and penetrating form of ionizing electromagnetic radiation, which can degrade NASA flight hardware. The main concern posed by such radiation is degradation of active electronic devices and, in some cases, diodes. Non-electronic components are only damaged at doses that far exceed the point where any electronic device would be destroyed. For the purposes of this document, flight hardware can be taken to mean an entire instrument, the flight electronics within the instrument or the individual microelectronic devices in the flight electronics. This document will discuss and describe the ways in which NASA flight hardware might be exposed to x-rays, what is and isn't a concern, and how to tell the difference. First, we must understand what components in flight hardware may be vulnerable to degradation or failure as a result of being exposed to ionizing radiation, such as x-rays. As stated above, bulk materials (structural metals, plastics, etc.) are generally only affected by ionizing radiation at very high dose levels. Likewise, passive electronic components (e.g. resistors, capacitors, most diodes) are strongly resistant to exposure to x-rays, except at very high doses. The main concerns arise when active components, that is, components like discrete transistors and microelectronic devices, are exposed to ionizing radiation. Active components are designed to respond to minute changes in currents and voltages in the circuit. As such, it is not surprising that exposure to ionizing radiation, which creates ionized and therefore electrically active particles, may degrade the way the hardware performs. For the most part, the mechanism for this degradation is trapping of the charges generated by ionizing radiation by defects in dielectric materials in the hardware. As such, the degree of damage is a function of both the quantity of ionizing radiation exposure and the physical characteristics of the hardware itself. The metric that describes the level of exposure to ionizing radiation is total ionizing dose (TID). The unit of TID is the rad, which is defined as 100 ergs absorbed per gram of material. Dose can be expressed in other units, for example grays (gy), where 1 gy = 100 rads. The actual fluence of radiation needed to deliver a rad depends on the absorbing material, so units of dose are usually stated in reference to the material of interest. That is, for microelectronic devices, the unit of dose is generally rad (Si) or rad (SiO2). However, the definition of absorbed dose in this fashion has the advantage that the type of radiation causing the ionization can be normalized so that a realistic and adequate comparison can be made. The sensitivity of microelectronic parts to TID varies over many orders of magnitude. (Note: Doses to humans are typically expressed in rems-or roentgen-equivalent-man-which measures tissue damage, and depends on the type of radiation, as well as the dose in rads.) Thus far, the "softest" parts tested at NASA showed damage at 500 rads (Si), while parts that are radiation-hardened by design can remain functional to doses on the order of 107 rads (Si). This broad range of sensitivity highlights one of the most important considerations when considering the effects of radiation on electronic parts: In order to determine whether a radiation exposure is a concern for a particular part, one must understand the technologies used in the part and their vulnerabilities to TID damage. A NASA radiation expert should be consulted to obtain such information.

X-ray↗

Software engineering methodologies and tools

Over the years many engineering disciplines have developed, including chemical, electronic, etc. Common to all engineering disciplines is the use of rigor, models, metrics, and predefined methodologies. Recently, a new engineering discipline has appeared on the scene, called software engineering. For over thirty years computer software has been developed and the track record has not been good. Software development projects often miss schedules, are over budget, do not give the user what is wanted, and produce defects. One estimate is there are one to three defects per 1000 lines of deployed code. More and more systems are requiring larger and more complex software for support. As this requirement grows, the software development problems grow exponentially. It is believed that software quality can be improved by applying engineering principles. Another compelling reason to bring the engineering disciplines to software development is productivity. It has been estimated that productivity of producing software has only increased one to two percent a year in the last thirty years. Ironically, the computer and its software have contributed significantly to the industry-wide productivity, but computer professionals have done a poor job of using the computer to do their job. Engineering disciplines and methodologies are now emerging supported by software tools that address the problems of software development. This paper addresses some of the current software engineering methodologies as a backdrop for the general evaluation of computer assisted software engineering (CASE) tools from actual installation of and experimentation with some specific tools.

Wilcox, Lawrence M.↗

A Model-Based, Bayesian Solution for Characterization of Complex Damage Scenarios in Aerospace Composite Structures

Ultrasonic damage detection and characterization is commonly used in nondestructive evaluation (NDE) of aerospace composite components. In recent years there has been an increased development of guided wave based methods. In real materials and structures, these dispersive waves result in complicated behavior in the presence of complex damage scenarios. Model-based characterization methods utilize accurate three dimensional finite element models (FEMs) of guided wave interaction with realistic damage scenarios to aid in defect identification and classification. This work describes an inverse solution for realistic composite damage characterization by comparing the wavenumber-frequency spectra of experimental and simulated ultrasonic inspections. The composite laminate material properties are first verified through a Bayesian solution (Markov chain Monte Carlo), enabling uncertainty quantification surrounding the characterization. A study is undertaken to assess the efficacy of the proposed damage model and comparative metrics between the experimental and simulated output. The FEM is then parameterized with a damage model capable of describing the typical complex damage created by impact events in composites. The damage is characterized through a transdimensional Markov chain Monte Carlo solution, enabling a flexible damage model capable of adapting to the complex damage geometry investigated here. The posterior probability distributions of the individual delamination petals as well as the overall envelope of the damage site are determined.

H. Reed↗

Quantitative software models for the estimation of cost, size, and defects

The presentation will provide a brief overview of the SQI measurement program as well as describe each of these models and how they are currently being used in supporting JPL project, task and software managers to estimate and plan future software systems and subsystems.

software metrics process improvement↗

Development of a Fully Automated Guided Wave System for In-Process Cure Monitoring of CFRP Composite Laminates

A guided wave-based in-process cure monitoring technique for carbon fiber reinforced polymer (CFRP) composites was investigated at NASA Langley Research Center. A key cure transition point (vitrification) was identified and the degree of cure was monitored using metrics such as amplitude and time of arrival (TOA) of guided waves. Using an automated system preliminarily developed in this work, high-temperature piezoelectric transducers were utilized to interrogate a twenty-four ply unidirectional composite panel fabricated from Hexcel (Registered Trademark) IM7/8552 prepreg during cure. It was shown that the amplitude of the guided wave increased sharply around vitrification and the TOA curve possessed an inverse relationship with degree of cure. The work is a first step in demonstrating the feasibility of transitioning the technique to perform in-process cure monitoring in an autoclave, defect detection during cure, and ultimately a closed-loop process control to maximize composite part quality and consistency.

Hudson, Tyler B.↗

Setting the Bar for the Replacement of the Probability of Collision Metric

To date, satellite conjunction assessment (CA) risk analysis has largely embraced the probability of collision (Pc) as the omnibus metric to evaluate collision likelihood, and its use in such assessments has mostly been straightforward: at the point at which a conjunction mitigation decision is required, the calculated Pc is compared to a threshold; and if the calculated Pc exceeds that threshold, then a mitigation action is warranted. With only minor variation, this approach is employed by major CA risk assessment centers (e.g., NASA, EUSST, CNES, JAXA) and is advanced as the preferred method in the published CA best practices handbooks. Despite this near unanimity of operational practice, there is a major strain of secondary literature critical of the Pc and willing to propose alternatives. Alfano (2005) pointed out the ability of the Pc to underrepresent the risk in certain situations and counselled a maximum Pc construct. Carpenter (2017, 2019) reiterated this criticism and proposed using instead a confidence interval on the miss distance. Balch et al. (2019) identified what they argued was a defect in the entire Bayesian Pc construct and believed that the use of a more conservative methodology based on covariance ellipsoid overlap was necessary. Delande (2022) introduced the framework of collision “plausibility” to the risk assessment process and sketched out how this might be used operationally. Elkantassi (2022) published a full development of the miss distance confidence interval approach and applied it to several worked examples. While these different approaches to collision risk assessment do differ in their details, they all converge on two central points: first, the Pc’s failure to give an adequate expression of the risk in dilution region situations is a fatal flaw; and second, a conjunction should be presumed risky and in need of mitigation until the evidence of the situation can establish otherwise. These criticisms, if correct, would counsel a number of modifications to current CA operational practice; as such, they force a re-examination of fundamental aspects of the CA problem, including the following: 1. Is the CA risk assessment a probability problem, a statistics problem, or something else? 2. If it is a statistics problem, does it lend itself naturally to a hypothesis test construction? 3. If it can be construed as a hypothesis test, what form should the null hypothesis take, to wit: what constraints exist on the choice of the null hypothesis, what selections are in best alignment with all of the attendant parameters of the problem, and what is implied philosophically by different choices? 4. What are the implications of using the different proposed risk assessment parameters for CA? This question should be answered both in determining how frequently the dilution region situation cited by the critics of the Pc actually appears in an operationally significant manner and the missed detection and false alarm rates of all of the proposed risk assessment metrics, compared both to the Pc and to each other. This paper explores and offers preliminary answers to the above questions, presenting a researched treatment of the philosophical nature of the CA problem and the null hypothesis choice that achieves the greatest consistency with all of the different aspects of operational CA conduct. It then profiles all of the different proposed risk assessment metrics enumerated in the earlier paragraph against an extremely large database of conjunction events at both the 550km and 700km altitudes. The combination of the philosophical exploration of the CA problem and the results of the profiling activity articulates what a risk assessment metric will need to demonstrate, in terms of both innate construction and performance, in order to be a true competitor to the Pc.

conjunction assessment↗

Sources of Uncertainty in Ultrasonic Phase-Based Assessment of Interfacial Stiffness in Adhesive Joints

Quantitative nondestructive evaluation (NDE) of adhesive joint strength is critical for certifying fastener-free bonded aerospace structures. Unfortunately, available adhesive NDE approaches are only suitable for detecting gross defects and delamination and cannot reliably detect variations in strength in intact bonds. Intact (i.e., nominally defect free) bonds are challenging to inspect because they, by definition, contain no macroscopic defects that would produce a strong NDE signature. Even in the absence of obvious defects, however, bond strength can vary substantially due to factors such as contamination, variations in the adhesive cure processes, and environmental exposure. For ultrasonic bond inspections, the effect of interactions from an imperfect adhesive interface are subtle and may include changes in the frequency content or phase of the ultrasonic signal. The bond condition can be deduced from these subtle changes in the acoustic response using an accompanying physics-based model of adhesive joint interaction. For example, researchers have used the spring network adhesion model of Baik and Thompson [1] to determine the interfacial stiffness of the joint from its ultrasonic response (e.g., [2]). This interfacial stiffness metric describes the bonds resistance to separation between the adhesive and adherent and has shown a strong correlation with joint strength. In this study, interfacial stiffness is assessed using the ultrasonic phase change associated with bond interaction in varying bond conditions. The phase change is measured precisely using a phase-locked-loop instrument over a swept range of frequencies. The phase transition at resonance, where the bond thickness is half the acoustic wavelength, produces a unique signature with which to fit a physics-based model. Interfacial stiffness is determined by minimizing the difference between the theoretical and experimental phase response. Experimental results are presented for glass specimens bonded with aerospace adhesives and a sensitivity analysis is performed to examine the effects of parameters that may be uncertain in the industrial inspection environment – namely bond thickness, adhesive and adherent properties, and porosity. The results are a first step toward an uncertainty quantified version of the measurement technique, show correlation between interfacial stiffness and bond strength, and are another key step toward maturing this approach for use in complex materials and joint geometries. [1] Baik, J.M. and Thompson, R.B., 1984. “Ultrasonic scattering from imperfect interfaces: a quasi-static model”. Journal of Nondestructive Evaluation, 4. [2] Haldren, H.A., Perey, D.F., Yost, W.T., Cramer, K.E., and Gupta, M.C., 2019. “Swept-frequency ultrasonic phase evaluation of adhesive bonding in tri-layer structures”. Journal of the Acoustical Society of America, 145.

Matt Webster↗