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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.

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36 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1972

Nondestructive testing of Scout rocket motors

The nondestructive tests applied to Scout rocket motors were reviewed and appraised. Analytical techniques were developed to evaluate the capabilities of the radiographic and ultrasonic procedures used. Major problem areas found were the inadequacy of high voltage radiography for detecting unbonds and propellant cracks having narrow widths, the inability to relate the ultrasonic signals received from flat-bottomed holes in standards to those received from real defects and in the general area of the specification of acceptance criteria and how these were to be met. To counter the deficiencies noted, analyses were conducted to the potential utility of radiometric, acoustic, holographic and thermographic techniques for motor and nozzle bond inspection, a new approach to qualifying magnetic particle inspection and the application of acoustic emission analysis to the evaluation of proof and leak test data.

Oaks, A. E.↗
NASA NTRS1976

Detection of tightly closed flaws by nondestructive testing (NDT) methods in steel and titanium

X-radiographic, liquid penetrant, ultrasonic, eddy current and magnetic particle testing techniques were optimized and applied to the evaluation of 4340 steel (180 KSI-UTS) and 6Al-4V titanium (STA) alloy specimens. Sixty steel specimens containing a total of 176 fatigue cracks and 60 titanium specimens containing a total of 135 fatigue cracks were evaluated. The cracks ranged in length from .043 cm (0.017 inch) to 1.02 cm (.400 inch) and in depth from .005 cm (.002 inch) to .239 cm (.094 inch) for steel specimens. Lengths ranged from .048 cm (0.019 inch) to 1.03 cm (.407 inch) and depths from 0.010 cm (.004 inch) to .261 cm (0.103 inch) for titanium specimens. Specimen thicknesses were nominally .152 cm (0.060 inch) and 0.635 cm (0.250 inch) and surface finishes were nominally 125 rms. Specimens were evaluated in the "as machined" surface condition, after etch surface and after proof loading in a randomized inspection sequence.

Rummel, W. D.↗
NASA NTRS1994

Inspecting Pipe Radiographically Through Asbestos Insulation

Welds between sections of insulated steampipe located and inspected radiographically. Unless need to repair defective weld, one avoids cost, time, and hazard of removing asbestos insulation. Enables inspectors to locate and evaluate nondestructively any weld in pipe system, without shutting down steam. Hidden weld joints first located by use of low-power fluoroscope, moved along pipe while technician observes fluoroscopic image. Low-energy x rays from fluoroscope penetrate insulation but not pipe. Weld bead appears in silhouette on fluoroscope screen. Technician then accurately marks weld sites on insulation for later inspection.

Gianettino, David P.↗
NASA NTRSDate not supplied

Automated Registration of Multi-Mode Nondestructive Evaluation Data

Registration techniques play a central role in applications of image processing to computer vision, medical imaging, and automatic target tracking. Feature-based techniques such as scale-invariant feature transform (SIFT) and speeded up robust features (SURF) are commonly used to register images derived from a single modality. However, SIFT and SURF struggle to register images from different modalities because the features tend to manifest rather differently and at sometimes very different length-scales. The most successful methods that have been developed to register multi-modal data use information-theoretic approaches. These methods play a key part in nondestructive evaluation scenarios where data that is collected by sensors of different modalities must be registered to be fused. In this paper, automated registration based on normalized mutual information is applied to align data derived from ultrasonic and radiographic inspections of (i) additively manufactured titanium alloy test coupons, and (ii) thin, lithium metal pouch-cell batteries. The quality of the registration is quantified in terms of computational resources and spatial accuracy. In the first case the X-ray computed tomography (XCT) data is captured on a region corresponding to a small subset of the ultrasonic data, while in the case of the lithium batteries the digital radiography (DR) captures a larger region of interest than the ultrasonic data. In both cases the radiographic data resolution is much higher than for ultrasound, but interestingly, in both cases the accuracy of the registration is approximately equal to two-to-three-pixel lengths in the ultrasonic images.

Nondestructive Evaluation↗
NASA NTRS1990

Development and applications of nondestructive evaluation at Marshall Space Flight Center

A brief description of facility design and equipment, facility usage, and typical investigations are presented for the following: Surface Inspection Facility; Advanced Computer Tomography Inspection Station (ACTIS); NDE Data Evaluation Facility; Thermographic Test Development Facility; Radiographic Test Facility; Realtime Radiographic Test Facility; Eddy Current Research Facility; Acoustic Emission Monitoring System; Advanced Ultrasonic Test Station (AUTS); Ultrasonic Test Facility; and Computer Controlled Scanning (CONSCAN) System.

Whitaker, Ann F.↗
NASA NTRS1968

Evaluation of methods for nondestructive testing of brazed joints

Evaluation of nondestructive methods of testing brazed joints reveals that ultrasonic testing is effective in the detection of nonbonds in diffusion bonded samples. Radiography provides excellent resolutions of void or inclusion defects, and the neutron radiographic technique shows particular advantage for brazing materials containing cadmium.

Kanno, A.↗
NASA NTRS2006

An Analysis of Nondestructive Evaluation Techniques for Polymer Matrix Composite Sandwich Materials

Structural sandwich materials composed of triaxially braided polymer matrix composite material face sheets sandwiching a foam core are being utilized for applications including aerospace components and recreational equipment. Since full scale components are being made from these sandwich materials, it is necessary to develop proper inspection practices for their manufacture and in-field use. Specifically, nondestructive evaluation (NDE) techniques need to be investigated for analysis of components made from these materials. Hockey blades made from sandwich materials and a flat sandwich sample were examined with multiple NDE techniques including thermographic, radiographic, and shearographic methods to investigate damage induced in the blades and flat panel components. Hockey blades used during actual play and a flat polymer matrix composite sandwich sample with damage inserted into the foam core were investigated with each technique. NDE images from the samples were presented and discussed. Structural elements within each blade were observed with radiographic imaging. Damaged regions and some structural elements of the hockey blades were identified with thermographic imaging. Structural elements, damaged regions, and other material variations were detected in the hockey blades with shearography. Each technique s advantages and disadvantages were considered in making recommendations for inspection of components made from these types of materials.

Cosgriff, Laura M.↗
NASA NTRS1972

Special nondestructive techniques for evaluating space shuttle surface insulation

NDT techniques have been developed for performing in-process evaluations for material variability and for process control. Several of these techniques show considerable promise for evaluating the reusable surface insulation during the operational phase of the shuttle. Considered are radiographic dosimetry, sonic velocity and modulus sounding, infrared coating evaluation, and beta backscatter monitoring of coating thickness.

Stinebring, R. C.↗
NASA NTRSDate not supplied

Overview of Nondestructive Evaluation Capabilities at NASA MSFC

Nondestructive evaluation (NDE) methods examine material integrity without impairing its usefulness. The NDE team at NASA Marshall Space Flight Center (MSFC) in Huntsville, Alabama is responsible for applying existing methods to new hardware designs and material systems, probability of detection studies to quantify detection capabilities, overseeing NDE requirements for flight hardware, inspecting development articles and flight hardware, engineering support for failure investigations, and investigating emerging NDE methods. NASA MSFC has been on the cutting edge of developing new NDE techniques, first for the space shuttle, then for composite structures, and most recently for additive manufacturing (AM). Standard in-house inspection capabilities include eddy current, magnetic particle, liquid penetrant, ultrasonic, and radiographic testing (including computed tomography). Other advanced inspection capabilities include infrared flash thermography, shearography, acoustic emission, and microwave/millimeter wave testing. Some recent research studies include AM probability of detection testing, investigating in-situ process monitoring methods for AM, and correlating the NDE response of true fatigue cracks with artificial notches.

nondestructive evaluation↗
NASA NTRS1991

Large area QNDE inspection for airframe integrity

Quantitative Nondestructive Evaluation (QNDE) technology is being developed to provide new options for cost effective inspection of airframes. An R&D effort based on five NDE technologies is addressing questions of structural bonding assessment, corrosion detection, multisite damage detection, and fatigue characterization. The research/applications are being conducted by prioritized focussing and staging of the following technologies: (1) thermal NDE; (2) ultrasonic NDE; (3) coherent optical NDE; (4) magnetic imaging NDE; and (5) radiographic NDE. The focus here is on the most recent applications of thermal NDE technology to large area inspection of lap-joint and stiffener bonds. The approach is based on pulsed radiant heating of the airframe and measurement of the surface temperature of the structure with an infrared imager. Several advantages of the technique are that it is noncontacting, inspects one square meter area in a period of less than 2 minutes and has no difficulty inspecting typical curvatures of the fuselage. Numerical models of heat flow in these geometries are used to determine appropriate techniques for reduction of the infrared images, thereby delineating regions of disbonds. These models are also used to determine the optimum heating and measurement times for maximizing the contrast between bonded and unbonded structures. Good agreement is found between these results and experimental measurements, and a comparison of the two are presented. Also presented are results of measurements on samples with fabricated defects which show the technique is able to clearly indicate regions of disbonds. Measurements on an airframe also clearly image subsurface structure.

Winfree, William P.↗
NASA NTRS1988

Nondestructive evaluation of sintered ceramics

Radiography and several acoustic and thermoacoustic microscopy techniques are investigated for application to structural ceramics for advanced heat engines. A comparison is made of the results obtained from the use of scanning acoustic microscopy (SAM), scanning laser acoustic microscopy (SLAM), and thermoacoustic microscopy (TAM). These techniques are evaluated on research samples of green and sintered monolithic silicon nitrides and silicon carbides in the form of modulus-of-rupture (MOR) bars containing deliberately introduced flaws. Strengths and limitations of the techniques are described, with the emphasis being on statistics of detectability of flaws that constitute potential fracture origins. Further, it is shown that radiographic evaluation and guidance helped develop uniform high-density Si3N4 MOR bars with improved four-point flexural strength (875, 544, and 462 MPa at room temperature, 1200 C, 1370 C, respectively) and reduced scatter in bend strength.

Baaklini, George Y.↗
NASA NTRS2006

Status of Thermal NDT of Space Shuttle Materials at NASA

Since the Space Shuttle Columbia accident, NASA has focused on improving advanced nondestructive evaluation (NDE) techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter's wing leading edge and nose cap. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Details of the analysis technique that has been developed to allow insitu inspection of a majority of shuttle RCC components is discussed. Additionally, validation testing, performed to quantify the performance of the system, will be discussed. Finally, the results of applying this technology to the Space Shuttle Discovery after its return from the STS-114 mission in July 2005 are discussed.

Cramer, K. Elliott↗
NASA NTRS1973

Detection of fatigue cracks by nondestructive testing methods

The effectiveness was assessed of various NDT methods to detect small tight cracks by randomly introducing fatigue cracks into aluminum sheets. The study included optimizing NDT methods calibrating NDT equipment with fatigue cracked standards, and evaluating a number of cracked specimens by the optimized NDT methods. The evaluations were conducted by highly trained personnel, provided with detailed procedures, in order to minimize the effects of human variability. These personnel performed the NDT on the test specimens without knowledge of the flaw locations and reported on the flaws detected. The performance of these tests was measured by comparing the flaws detected against the flaws present. The principal NDT methods utilized were radiographic, ultrasonic, penetrant, and eddy current. Holographic interferometry, acoustic emission monitoring, and replication methods were also applied on a reduced number of specimens. Generally, the best performance was shown by eddy current, ultrasonic, penetrant and holographic tests. Etching provided no measurable improvement, while proof loading improved flaw detectability. Data are shown that quantify the performances of the NDT methods applied.

Anderson, R. T.↗
NASA NTRS2005

The Application of Infrared Thermographic Inspection Techniques to the Space Shuttle Thermal Protection System

The Nondestructive Evaluation Sciences Branch at NASA s Langley Research Center has been actively involved in the development of thermographic inspection techniques for more than 15 years. Since the Space Shuttle Columbia accident, NASA has focused on the improvement of advanced NDE techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter s wing leading edge. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can be used to inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Principal Component Analysis (PCA) has been shown effective for reducing thermographic NDE data. A typical implementation of PCA is when the eigenvectors are generated from the data set being analyzed. Although it is a powerful tool for enhancing the visibility of defects in thermal data, PCA can be computationally intense and time consuming when applied to the large data sets typical in thermography. Additionally, PCA can experience problems when very large defects are present (defects that dominate the field-of-view), since the calculation of the eigenvectors is now governed by the presence of the defect, not the "good" material. To increase the processing speed and to minimize the negative effects of large defects, an alternative method of PCA is being pursued where a fixed set of eigenvectors, generated from an analytic model of the thermal response of the material under examination, is used to process the thermal data from the RCC materials. Details of a one-dimensional analytic model and a two-dimensional finite-element model will be presented. An overview of the PCA process as well as a quantitative signal-to-noise comparison of the results of performing both embodiments of PCA on thermographic data from various RCC specimens will be shown. Finally, a number of different applications of this technology to various RCC components will be presented.

Cramer, K. E.↗
NASA NTRS2006

The Application of Principal Component Analysis Using Fixed Eigenvectors to the Infrared Thermographic Inspection of the Space Shuttle Thermal Protection System

The Nondestructive Evaluation Sciences Branch at NASA s Langley Research Center has been actively involved in the development of thermographic inspection techniques for more than 15 years. Since the Space Shuttle Columbia accident, NASA has focused on the improvement of advanced NDE techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter s wing leading edge. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can be used to inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Principal Component Analysis (PCA) has been shown effective for reducing thermographic NDE data. A typical implementation of PCA is when the eigenvectors are generated from the data set being analyzed. Although it is a powerful tool for enhancing the visibility of defects in thermal data, PCA can be computationally intense and time consuming when applied to the large data sets typical in thermography. Additionally, PCA can experience problems when very large defects are present (defects that dominate the field-of-view), since the calculation of the eigenvectors is now governed by the presence of the defect, not the good material. To increase the processing speed and to minimize the negative effects of large defects, an alternative method of PCA is being pursued when a fixed set of eigenvectors is used to process the thermal data from the RCC materials. These eigen vectors can be generated either from an analytic model of the thermal response of the material under examination, or from a large cross section of experimental data. This paper will provide the details of the analytic model; an overview of the PCA process; as well as a quantitative signal-to-noise comparison of the results of performing both embodiments of PCA on thermographic data from various RCC specimens. Details of a system that has been developed to allow insitu inspection of a majority of shuttle RCC components will be presented along with the acceptance test results for this system. Additionally, the results of applying this technology to the Space Shuttle Discovery after its return from flight will be presented.

Cramer, K. Elliott↗
NASA NTRS2014

The Effect of Experimental Variables on Industrial X-Ray Micro-Computed Sensitivity

A study was performed on the effect of experimental variables on radiographic sensitivity (image quality) in x-ray micro-computed tomography images for a high density thin wall metallic cylinder containing micro-EDM holes. Image quality was evaluated in terms of signal-to-noise ratio, flaw detectability, and feature sharpness. The variables included: day-to-day reproducibility, current, integration time, voltage, filtering, number of frame averages, number of projection views, beam width, effective object radius, binning, orientation of sample, acquisition angle range (180deg to 360deg), and directional versus transmission tube.

X-ray Computed Tomography↗
NASA NTRS1986

NDE of advanced ceramics

Radiographic, ultrasonic, and scanning laser acoustic microscopy (SLAM) techniques were used to characterize silicon nitride and silicon carbide modulus-of-rupture test specimens in various stages of fabrication. Conventional and microfocus X-ray techniques were found capable of detecting minute high-density inclusions in as-received powders, green compacts, and fully densified specimens. Significant density gradients in sintered bars were observed by radiography, ultrasonic velocity, and SLAM. Ultrasonic attenuation was found sensitive to microstructural variations due to grain and void morphology and distribution. SLAM was capable also of detecting voids, inclusions, and cracks in finished test bars. Consideration is given to the potential for applying thermoacoustic microscopy techniques to green and densified ceramics. Some limitations and the detection probability statistics of the aforementioned nondestructive evaluation (NDE) processes are also discussed.

Klima, S. J.↗
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↗