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NASA NTRS1995

Shearographic non-destructive evaluation of the Space Shuttle

Preliminary results of shearographic inspections of the shuttle external tank (ET) spray-on foam insulation (SOFI) and solid rocket booster (SRB) Marshall sprayable ablative (MSA-2) epoxy-cork thermal protection systems (TPS) and remote manipulator system (RMS) honeycomb are presented. Debonding SOFI or MSA-2 damage the orbiter belly tile and exposes the ET/SRB to thermal loading. Previous work with the ET/SRB showed promising results with shearography. The first area investigated was the jack pad close-out, one of many areas on the ET where foam is applied at KSC. Voids 0.375 inch were detected in 1.75 inch thick foam using a pressure reduction of less dm 0.4 psi. Of primary interest are areas of the ET that directly face the orbiter tile TPS. It is estimated that 90% of tile TPS damage on the orbiter 'belly' results from debonding SOFI during ascent. Test panels modeling these areas were manufactured with programmed debonds to determine the sensitivity of shearography as a function of debond size, SOFI thickness, and vacuum. Results show a Probability of Detection (POD) of .95 or better for of debonds with a diameter equal to the SOFI thickness at less than 0.4 psi pressure reduction. Preliminary results are also presented on inspections of MSA-2 and the remote manipulator system (RMS) honeycomb material.

Davis, Christopher K.↗
NASA NTRS1995

Shearographic non-destructive evaluation of space shuttle thermal protection systems

Preliminary results of shearographic inspections of the shuttle external tank (ET) spray-on foam insulation (SOFI) and solid rocket booster (SRB) Marshall sprayable ablative (MSA-2) epoxy-cork thermal protection systems (TPS) are presented. Debonding SOFI or MSA-2 damage the orbiter 'belly' tile and exposes the ET/SRB to thermal loading. Previous work with the ET/SRB showed promising results with shearography. The first area investigated was the jack pad close-out, one of many areas on the ET where foam is applied at KSC. Voids 0.375 inch were detected in 1.75 inch thick foam using a pressure reduction of less than 0.4 psi. Of primary interest are areas of the ET that directly face the orbiter tile TPS. It is estimated that 90% of tile TPS damage on the orbiter 'belly' results from debonding SOFI during ascent. Test panels modeling these areas were manufactured with programmed debonds to determine the sensitivity of shearography as a function of debond size, SOFI thickness and vacuum. Results show repeatable detection of debonds with a diameter approximately half the SOFI thickness at less than 0.4 psi pressure reduction. Preliminary results are also presented on inspections of MSA-2 and the remote manipulator system (RMS) honeycomb material

Hooker, Jeffrey A.↗
NASA NTRS1995

Shearographic Non-destructive Evaluation of Space Shuttle Thermal Protection Systems

Preliminary results of shearographic inspections of the shuttle external tank (ET) spray-on foam insulation (SOFI) and solid rocket booster (SRB) Marshall sprayable ablative (MSA-2) epoxy-cork thermal protection systems (TPS) are presented. Debonding SOFI or MSA-2 damage the orbiter 'belly' tile and exposes the ET/SRB to thermal loading. Previous work with the ET/SRB showed promising results with shearography. The first area investigated was the jack pad close-out, one of many areas on the ET where foam is applied at KSC. Voids 0.375 inch were detected in 1.75 inch thick foam using a pressure reduction of less than 0.4 psi. Of primary interest are areas of the ET that directly face the orbiter tile TPS. It is estimated that 90% of tile TPS damage on the orbiter 'belly' results from debonding SOFI during ascent. Test panels modeling these areas were manufactured with programmed debonds to determine the sensitivity of shearography as a function of debond size, SOFI thickness and vacuum. Results show repeatable detection of debonds with a diameter approximately half the SOFI thickness at less than 0.4 psi pressure reduction. Preliminary results are also presented on inspections of MSA-2 and the remote manipulator system (RMS) honeycomb material.

Davis, Christopher K.↗
NASA NTRS1995

Impact damage resistance and residual property assessment of (0/+/-45/90)s SCS-6/Timetal 21S

The impact damage resistance and residual mechanical properties of (0/ +/- 45/90)s SCS-6/Timetal 21S composites were evaluated. Both quasi-static indentation and drop-weight impact tests were used to investigate the impact behavior at two nominal energy levels (5.5 and 8.4 J) and determine the onset of internal damage. Through x-ray inspection, the extent of internal damage was characterized non-destructively. The composite strength and constant amplitude fatigue response were evaluated to assess the effects of the sustained damage. Scanning electron microscopy was used to characterize internal damage from impact in comparison to damage that occurs during mechanical loading alone. The effect of stacking sequence was examined by using specimens with the long dimension of the specimen both parallel (longitudinal) and perpendicular (transverse) to the 0 deg fiber direction. Damage in the form of longitudinal and transverse cracking occurred in all longitudinal specimens tested at energies greater than 6.3 J. Similar results occurred in the transverse specimens tested above 5.4 J. Initial load drop, characteristic of the onset of damage, occurred on average at 6.3 J in longitudinal specimens and at 5.0 J in transverse specimens. X-ray analysis showed broken fibers in the impacted region in specimens tested at the higher impact energies. At low impact energies, visible matrix cracking may occur, but broken fibers may not. Matrix cracking was noted along fiber swims and it appeared to depend on the surface quality of composite. At low impact energies, little damage has been incurred by the composite and the residual strength and residual life is not greatly reduced as compared to an undamaged composite. At higher impact energies, more damage occurred and a greater effect of the impact damage was observed.

Miller, Jennifer L.↗
NASA NTRS1996

Non-destructive evaluation of composites

The composite materials have been used in aerospace industries for quite some time. Several non-destructive evaluation (NDE) methods have been developed to inspect composites in order to detect flaws, matrix cracking, and delamination. These methods include ultrasonics, acoustic emission, shearography, thermography, X-ray, and digital image correlation. The NDE Branch of Marshall Space Flight Center has recently acquired a thermal imaging NDE system. The same system has been used at NASA Langley Research Center for detecting disbonds. In order to compare different NDE methods, three carbon/carbon composite panels were used for experiment using ultrasonic C-scan, shearography, and thermography methods. These panels have teflon inserts to simulate the delamination between plies in a composite panel. All three methods have successfully located the insert. The experiment and results are presented in the following sections.

Chu, Tsuchin Philip↗
NASA NTRS1998

Health Monitoring of Composite Material Structures Using a Vibrometry Technique

Non-destructive evaluation (NDE) methods for quantifying and locating damage are essential for inspecting structures to ensure safety and reliability. Transmittance function monitoring is a potentially new NDE technique being tested as a tool to detect, quantify, and locate damage on flexible structures. The technique has a large spatial range that is practical for detecting damage on large composite material structures such as a reusable launch vehicle. The Transmittance Function (TF) theory is based on structural dynamics principles that define how vibration at one point in a structure is related to a force at another point. This relationship is called the Frequency Response Function (FRF). A Transmittance Function (TF) is derived as the ratio of FRFs, and can detect damage because the FRFs change due to damage. If one excitation is used for the testing, the force does not need to be measured to compute the TF. In the damage detection procedure, the structure is subjected to wide-band vibration and TFs are computed between different accelerometers to detect changes in the structure, presumably due to damage. In the first year of the project the TF method was tested on a bolted panel, a curved panel, and beams, all made of fiberglass. It was shown that damage could be detected using low frequency vibration, 250 to 1,250 Hz. The technique is sensitive to damage, but it requires storage of historical or pre-damage TFs for the healthy structure. This would become a large data storage requirement for large structures. Thus one objective for the second year of the project was to eliminate the need to store historical data. The second year report gives details of how storage of historical data was eliminated. Further results of testing panel structures are also given.

Schulz, Mark J.↗
NASA NTRS1990

Non-Destructive Testing Scanner

Bio-Imaging Research's technology that originated in an aerospace program has come full circle with a new aerospace adaptation called the Advanced Computed Tomography Inspection System, or ACTIS. The medical version of CT scans the human body for tumors or other abnormalities, the ACTIS system finds imperfections in aerospace structures and components, such as castings, assemblies, rocket motors and nozzles. ACTIS is described by its developer as the most versatile CT scanner available for non-destructive testing applications. ACTIS is a variable geometry system. ACTIS source and detectors can be moved closer together or farther apart to optimize the geometry for different sizes of test objects. The combination of variable geometry, three sources, and focusing detectors makes ACTIS cost effective for a broad range of applications. System can scan anything from very small turbine blades to large rocket assemblies.

Source record↗
NASA NTRS2003

Shearography for Non-Destructive Evaluation with Applications to BAT Mask Tile Adhesive Bonding and Specular Surface Honeycomb Panels

In this report we examine the applicability of shearography techniques for nondestructive inspection and evaluation in two unique application areas. In the first application, shearography is used to evaluate the quality of adhesive bonds holding lead tiles to the BAT gamma ray mask for the NASA Swift program. By exciting the mask with a vibration, the more poorly bonded tiles can be distinguished by their greater displacement response, which is readily identifiable in the shearography image. A quantitative analysis is presented that compares the shearography results with a destructive pull test measuring the force at bond failure. Generally speaking, the results show good agreement. Further investigation would be useful to optimize certain test parameters such as vibration frequency and amplitude. The second application is to evaluate the bonding between the skin and core of a honeycomb structure with a specular (mirror-like) surface. In standard shearography techniques, the object under test must have a diffuse surface to generate the speckle patterns in laser light, which are then sheared. A novel configuration using the specular surface as a mirror to image speckles from a diffuser is presented, opening up the use of shearography to a new class of objects that could not have been examined with the traditional approach. This new technique readily identifies large scale bond failures in the panel, demonstrating the validity of this approach. For the particular panel examined here, some scaling issues should be examined further to resolve the measurement scale down to the very small size of the core cells. In addition, further development should be undertaken to determine the general applicability of the new approach and to establish a firm quantitative foundation.

Lysak, Daniel B.↗
NASA NTRS1998

A New Approach to Overcoming Spatial Aliasing in Structural Damage Detection

Aircraft, reusable launch vehicles,unmanned aircraft, and other advanced structures are being built using lightweight composite materials/metals with design safety factors as low as 1.25. These advanced structures operate in uncertain and severe environments and are susceptible to damage such as delamination, fiber/matrix damage, hydrothermal strain in composite materials, and fatigue and cracking in metals. To ensure human safety and load-bearing integrity these structures must be inspected to detect and locate often invisible damage and faults before they become catastrophic. Conventional methods of non-destructive evaluation sometimes miss significant damage and are time consuming and expensive to perform. In contrast, vibrometry or vibration signature techniques are a global method of structural integrity monitoring that potentially can efficiently detect damage on large structures, including damage that is away from sensor locations, and in the interior of structures. However, a barrier problem in damage detection using vibration measurements is the need to measure the vibration response at a large number of points on the structure. Typically, model reduction or expansion procedures such as Guyan reduction or dynamic expansion are attempted to overcome the problem of insufficient measurements or spatial aliasing. These approaches depend on using information from the healthy model, and thus put error into the reduction used to represent the damaged structure. In this paper, a Frequency Response Function technique is used to detect damage to a fixed-free beam. The technique uses measured frequency response functions from the healthy structure as reference data, and then monitors vibration measurements during the life of the structure to detect damage. In an analytical simulation using a finite-element model of a beam, damage was located using only sparse measurements because the technique uses both rotation and translation measurements from the damaged structure.

Schulz, Mark J.↗
NASA NTRS2004

Development of Non Destructive Evaluation Techniques for the In-Situ Inspection of the Orbiter's Thermal Protection System

One of the Columbia Accident Investigation Board's (CAB) recommendation is to develop and implement an inspection plan to determine the structural integrity of all Reinforced Carbon-Carbon (RCC) system components that make part of the Space Shuttle's thermal protection system. This presentation focuses on the efforts to leverage non-destructive evaluation (NDE) expertise from academia, private industry, and government agencies resulting in the design of a comprehensive health monitoring program for RCC components. The different NDE techniques that were considered are presented along with the chosen techniques and preliminary inspection results of RCC materials.

Hernandez, Jose M.↗
NASA NTRS2005

Rotordynamic Analysis and Feasibility Study of a Disk Spin Test Facility for Rotor Health Monitoring

Recently, National Aeronautics and Space Administration (NASA) initiated a program to achieve the significant improvement in aviation safety. One of the technical challenges is the design and development of accelerated experiments that mimic critical damage cases encountered in engine components. The Nondestructive Evaluation (NDE) Group at the NASA Glenn Research Center (GRC) is currently addressing the goal concerning propulsion health management and the development of propulsion system specific technologies intended to detect potential failures prior to catastrophe. For this goal the unique disk spin simulation system was assembled at NASA GRC, which allows testing of rotors with the spinning speeds up to 10K RPM, and at the elevated temperature environment reaching 540 C (1000 F). It is anticipated that the facility can be employed for detection of Low Cycle Fatigue disk cracking and further High Cycle Fatigue blade vibration. The controlled crack growth studies at room and elevated temperatures can be conducted on the turbine wheels, and various NDE techniques can be integrated and assessed as in-situ damage monitoring tools. Critical rotating parts in advanced gas turbine engines such as turbine disks frequently operate at high temperature and stress for long periods of time. The integrity of these parts must be proven by non-destructive evaluation (NDE) during various machining steps ranging from forging blank to finished shape, and also during the systematic overhaul inspections. Conventional NDE methods, however, have unacceptable limits. Some of these techniques are time-consuming and inconvenient for service aircraft testing. Almost all of these techniques require that the vicinity of the damage is known in advance. These experimental techniques can provide only local information and no indication of the structural strength at a component and/or system level. The shortcomings of currently available NDE methods lead to the requirement of new damage detection techniques that can provide global information on the rotating components/system, and, in addition, they do not require direct human access to the operating system. During this period of research considerable effort was directed towards the further development of experimental facility and development of the vibration-based crack detection methodology for rotating disks and shafts. A collection of papers and reports were written to describe the results of this work. The attached captures that effort and represents the research output during the grant period.

Sawicki, Jerzy T.↗
NASA NTRS2006

Nondestructive Evaluation of Foam Insulation on the Space Shuttle External Tank

Foam loss on the External Tank (ET) during launch can be caused by a number of factors. Voids are the best understood mechanism of foam loss, although it is known that delaminations, cracks and crushed foam can also lead to liberation of foam. Shortly after the Columbia accident, work began on non-destructive evaluation of foam targeted at finding voids and delaminations. After several months of searching for candidate methods capable of inspecting ET foam, the five most promising techniques were taken through a blind test and narrowed down to two methods to develop and use for inspection of the ET. These methods were backscatter radiography and terahertz imaging. The backscatter radiography system measures a test part by detecting Compton backscattered x-ray energy generated by a collimated beam of x-rays directed at the test subject. This collimated beam is scanned across the subject, recording scatter intensity data one pixel at a time until the area of interest is covered. The resulting data can be used to generate an image similar to a radiograph. Some depth information can be gathered utilizing apertures or collimation on the detectors. The detectors are located around the collimated source, making this a single sided inspection. The void detection limit with the currently utilized system is around 0.5 inches in diameter by 0.2 inches high. The terahertz imaging system inspects a test part by utilizing a transceiver to emit a pulse focused at the aluminum skin of the ET, which reflects it back to the transceiver where it is analyzed. The transceiver is scanned across the area of interest until a measurement has been taken at every location. Amplitude, time delay and frequency content are examined to note any discontinuities which may be the result of a void or other type of defect. The pulse currently utilized is in the millimeter wave regime. The void detection limit with this system is around 0.5 inches in diameter by 0.2 inches high. With increased interest in other causes of foam loss following the flight of Discovery in July 2005, laser shearography was added to the techniques used for inspecting ET foam. The shearography method records a sheared image of a laser speckle pattern projected on a test part before And after some sort of excitation. The resultant fringe pattern allows the slope of the out of plane displacement to be measured. For crushed and delaminated foam applications, a non-contact air coupled acoustic force is used to excite the surface of the foam. Regions without defects tend to respond differently to the sound energy than do regions with defects, generating a map of the foam integrity. Foam crushed to a depth of about 0.1 inches is detectable with shearography even after it has relaxed to its original shape.

Richter, Joel↗
NASA NTRS1996

Finite Element Modeling of the Thermographic Inspection for Composite Materials

The performance of composite materials is dependent on the constituent materials selected, material structural geometry, and the fabrication process. Flaws can form in composite materials as a result of the fabrication process, handling in the manufacturing environment, and exposure in the service environment to anomalous activity. Often these flaws show no indication on the surface of the material while having the potential of substantially degrading the integrity of the composite structure. For this reason it is important to have available inspection techniques that can reliably detect sub-surface defects such as inter-ply disbonds, inter-ply cracks, porosity, and density changes caused by variations in fiber volume content. Many non-destructive evaluation techniques (NDE) are capable of detecting sub-surface flaws in composite materials. These include shearography, video image correlation, ultrasonic, acoustic emissions, and X-ray. The difficulty with most of these techniques is that they are time consuming and often difficult to apply to full scale structures. An NDE technique that appears to have the capability to quickly and easily detect flaws in composite structure is thermography. This technique uses heat to detect flaws. Heat is applied to the surface of a structure with the use of a heat lamp or heat gun. A thermographic camera is then pointed at the surface and records the surface temperature as the composite structure cools. Flaws in the material will cause the thermal-mechanical material response to change. Thus, the surface over an area where a flaw is present will cool differently than regions where flaws do not exist. This paper discusses the effort made to thermo-mechanically model the thermography process. First the material properties and physical parameters used in the model will be explained. This will be followed by a detailed discussion of the finite element model used. Finally, the result of the model will be summarized along with recommendations for future work.

Bucinell, Ronald B.↗
NASA NTRS2004

RCC NDE Update

This slide presentation reviews non-destructive evaluation (NDE) techniques of Reinforced Carbon-Carbon (RCC) materials and the progress involved in bringing the technology to technological maturity. Included is information about the test specimens, thermographic, ultrasonic, eddy current, and radiographic inspection of RCC materials.

Hernandez, Jose M.↗
NASA NTRS1993

Characteristics of Ferromagnetic Flux Focusing Lens in the Development of Surface/Subsurface Flaw Detector

Electromagnetic NDE techniques have in the past steered away from the use of ferromagnetic materials. Although their high permeabilities lead to increased field levels, the properties of ferrous elements in the presence of alternating magnetic fields are difficult to determine. In addition, their use leads to losses which can be minimized through the use of low conductivity ferrites. In fact, the eddy current probes which do incorporate ferromagnetic materials have focused on these losses and the shielding which can be obtained by surrounding a probe with a high permeability, conducting material. Eddy current probes enclosed in conducting and magnetic shields have been used to prevent the generated fields from interacting with materials in the vicinity of the probe, such as when testing near material boundaries. A recent invention has used ferromagnetic shielding to magnetically separate individual concentric eddy current probes in order to eliminate cross-talk between the probes so that simultaneous detection of different types of flaws at different depths can be achieved. In contrast to the previous uses of ferromagnetic materials purely as magnetic shields, an electromagnetic flaw detector recently developed at NASA Langley Research Center takes advantage of the flux focusing properties of a ferromagnetic mild steel in order to produce a simple, effective device for the non-destructive evaluation of conducting materials. The Flux Focusing Eddy Current Probe has been shown to accurately measure material thickness and fatigue damage. The straight forward flaw response of the probe makes the device ideal for rapid inspection of large structures, and has lead to its incorporation in a computer controlled search routine to locate fatigue crack tips and monitor experimental fatigue crack growth experiments.

Wincheski, Buzz↗
NASA NTRS1993

Industrial Inspection System

ACTIS+ is a smaller, personal computer version of ACTIS, a computed tomography system which finds its origins in the Apollo lunar landing research. It is used to identify imperfections in aerospace structures and components. Designed to be added to an existing real time radiography system, its components include a high precision rotation/elevation manipulator, color image monitor, graphical user interface monitor, and PC compatible workstation. Cross-sectional CT images are more detailed than radiographic images and the high speed scanning feature offers the capability for 100 percent inspection in a production environment. Bio-Imaging Research, Inc. (BIR) originally developed ACTIS for Marshall Space Flight Center (MSFC), and commercial units were sold to aerospace manufacturers. The technology was refined for ACTIS+, which is principally used in non-destructive testing.

Source record↗
NASA NTRS2003

Design of a Borescope for Extravehicular Non-Destructive Applications

Anomalies such as corrosion, structural damage, misalignment, cracking, stress fiactures, pitting, or wear can be detected and monitored by the aid of a borescope. A borescope requires a source of light for proper operation. Today s current lighting technology market consists of incandescent lamps, fluorescent lamps and other types of electric arc and electric discharge vapor lamp. Recent advances in LED technology have made LEDs viable for a number of applications, including vehicle stoplights, traffic lights, machine-vision-inspection, illumination, and street signs. LEDs promise significant reduction in power consumption compared to other sources of light. This project focused on comparing images taken by the Olympus IPLEX, using two different light sources. One of the sources is the 50-W internal metal halide lamp and the other is a 1 W LED placed at the tip of the insertion tube. Images acquired using these two light sources were quantitatively compared using their histogram, intensity profile along a line segment, and edge detection. Also, images were qualitatively compared using image registration and transformation [l]. The gray-level histogram, edge detection, image profile and image registration do not offer conclusive results. The LED light source, however, produces good images for visual inspection by an operator. Analysis using pattern recognition using Eigenfaces and Gaussian Pyramid in face recognition may be more useful.

Bachnak, Rafic↗
NASA NTRS1991

Current and future developments in civil aircraft non-destructive evaluation from an operator's point of view

In June, 1988, the first International Conference on aging aircraft was held to address nondestructive tests (NDT) of aging aircraft and other issues. From this meeting, a research program was initiated and funded by the FAA. As a result of this program, a lot of work has been done to study current NDT practices in the aviation industry and secondly, to research and develop new NDT methods to improve the reliability and efficiency of in-service inspection of aircraft structures and powerplants. The following is an overview of the current and future developments in civil aircraft NDT, as viewed by an air carrier and the concerns for NDT in the future.

Aging Aircraft↗