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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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All sources NASA NTRS DOE OSTI

NASA NTRS1991

Mechanical behavior of fiber reinforced SiC/RBSN ceramic matrix composites - Theory and experiment

The mechanical behavior of continuous fiber reinforced SiC/RBSN (Reaction Bonded Silicon Nitride) composites with various fiber contents is evaluated. Both catastrophic and noncatastrophic failures are observed in tensile specimens. Damage and failure mechanisms are identified via in-situ monitoring using NDE (nondestructive evaluation) techniques throughout the loading history. Effects of fiber/matrix interface debonding (splitting) parallel to fibers are discussed. Statistical failure behavior of fibers is also observed, especially when the interface is weak. Micromechanical models incorproating residual stresses to calculate the critical matrix cracking strength, ultimate strength, and work of pull-out are reviewed and used to predict composite response. For selected test problems, experimental measurements are compared to analytical predictions.

Chulya, Abhisak↗

NASA NTRS1994

Unique methods for on-orbit structural repair, maintenance, and assembly

This paper reviews the MDA independent research and development (IRAD) efforts since 1986 in the development of two distinctly different approaches to on-orbit tube repair: (1) one-piece mechanical tube fittings that are forced, under pressure, onto the tube outer surface to effect the repair; and (2) electron beam weldings as demonstrated with the Paton-developed universal hand tool (UHT) space welding system for the repair of fluid lines and tubular components. Other areas of potential on-orbit repair using the UHT include damage to the flat or curved surfaces of habitation modules and truss assemblies. This paper will also address MDA evaluation of the Paton UHT system for on-orbit coating, cleaning, brazing, and cutting of metals. MDA development of an on-orbit compatible nondestructive evaluation (NDE) system for the inspection of tube welds is an important part of this complete space welding capability and will be discussed in a separate paper.

Anderson, Ray↗

NASA NTRS2001

Characterization of Ceramic Matrix Composite Combustor Components: Pre and Post Exposure

The pursuit of lower emissions and higher performance from gas turbine engines requires the development of innovative concepts and the use of advanced materials for key engine components. One key engine component is the combustor, where innovative design and material improvements have the potential to lower emissions. Efforts to develop a High Speed Civil Transport with low emissions were focused on the evaluation of combustor concepts with liners fabricated from a ceramic matrix composite of silicon carbide fibers in a silicon carbide matrix (SiC/SiC). The evaluation of SiC/SiC composites progressed from simple coupons (to establish a first-order database and identify operant failure mechanisms and damage accumulation processes), to feature-based subelements (to assess fabricability and in situ material response), to actual components (to assess structural integrity, dimensional, and compositional fidelity) tested under simulated engine conditions. As in the case of all evolutionary material and process work, a key element to resolving fabrication issues is the evaluation of witness areas taken from fabricated components before testing the actual component. The witness material from these components allowed microstructural and mechanical testing to be performed and compared to the ideal, flat panel, conditions and data that are typical of basic characterization. This also allowed samples of similar design to be taken from components after 115 hours of combustion exposure. Testing consisted of tensile, double notch shear, ring burst, and thermal conductivity that sampled various regions of the components. The evaluation of the witness material allowed an understanding of the fabrication process, highlighting critical issues, in an early phase of the learning curve development of these configuration and material unique parts. Residual property testing, after exposure, showed if degradation of the material under actual service conditions was occurring. This paper will present the results of this critical testing. Evaluations that consider the degree of complexity of the fabricated part were established to relate in situ performance to that of flat panel based coupons. Nondestructive evaluation was used throughout the evaluation process. These results will also be discussed as an aid in understanding the test results.

Ojard, G.↗

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 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 NTRS1983

Eddy current X-Y scanner system

The Nondestructive Evaluation Branch of the Materials and Processes Laboratory became aware of a need for a miniature, portable X-Y scanner capable of performing eddy current or other nondestructive testing scanning operations such as ultrasonic, or small areas of flat plate. The technical description and operational theory of the X-Y scanner system designed and built to fulfill this need are covered. The scanner was given limited testing and performs according to its design intent, which is to scan flat plate areas of approximately 412 sq cm (64 sq in) during each complete cycle of scanning.

Kurtz, G. W.↗

NASA NTRS2004

Applicability of a Crack-Detection System for Use in Rotor Disk Spin Test Experiments Being Evaluated

Engine makers and aviation safety government institutions continue to have a strong interest in monitoring the health of rotating components in aircraft engines to improve safety and to lower maintenance costs. To prevent catastrophic failure (burst) of the engine, they use nondestructive evaluation (NDE) and major overhauls for periodic inspections to discover any cracks that might have formed. The lowest cost fluorescent penetrant inspection NDE technique can fail to disclose cracks that are tightly closed during rest or that are below the surface. The NDE eddy current system is more effective at detecting both crack types, but it requires careful setup and operation and only a small portion of the disk can be practically inspected. So that sensor systems can sustain normal function in a severe environment, health-monitoring systems require the sensor system to transmit a signal if a crack detected in the component is above a predetermined length (but below the length that would lead to failure) and lastly to act neutrally upon the overall performance of the engine system and not interfere with engine maintenance operations. Therefore, more reliable diagnostic tools and high-level techniques for detecting damage and monitoring the health of rotating components are very essential in maintaining engine safety and reliability and in assessing life.

Abdul-Aziz, Ali↗

NASA NTRS1999

NDE Process Development Specification for SRB Composite Nose Cap

The Shuttle Upgrade program is a continuing improvement process to enable the Space Shuttle to be an effective space transportation vehicle for the next few decades. The Solid Rocket Booster (SRB), as a component of that system, is currently undergoing such an improvement. Advanced materials, such as composites, have given us a chance to improve performance and to reduce weight. The SRB Composite Nose Cap (CNC) program aims to replace the current aluminum nose cap, which is coated with a Thermal Protection System and poses a possible debris hazard, with a lighter, stronger, CNC. For the next 2 years, this program will evaluate the design, material selection, properties, and verification of the CNC. This particular process specification cites the methods and techniques for verifying the integrity of such a nose cap with nondestructive evaluation.

Suits, M.↗

NASA NTRSDate not supplied

Evaluation Marcelling in Composites using Ultrasonic Guided Wave

Thermoplastic composite (TPC) material seldom manifests in-plane fiber waviness during manufacturing. In-plane fiber waviness is called marcelling. Marcelling com-promises the composite strength and performance. When present in a structure, marcelling is not only a surface defect but can extend partially along the thickness of the composite. There is no established nondestructive evaluation (NDE) method to detect and quantify marcelling in composite. Ultrasonic guided waves can saturate the complete thickness of a composite structure. Thus, physics of guided wave creates an opportunity to detect and quantify the marcelling in composites. Before guided waves could be used to detect marcelling, it is necessary to quantify the marcelling in the structure and identify the marcelling affected zones (MAZE). In this research first, high frequency scanning acoustic microscopy (SAM) was performed to quantify the marcelling and statistical distribution of the defects at different MAZE was obtained. Next the MAZE with known statistical distribution of quantified marcelling (marcelling wavelength and marcelling amplitude) was inspected using ultrasonic guided wave setup. The method quantified the guided wave feature as a function of quantitative degree of marcelling. The overarching objective of this research is to implement post process NDE inspection of TPC large structures where in plane fiber waviness or marcelling can be detected and MAZEs could be identified. Primary fining is that the reduction of wave velocity and amplitude of ultrasonic guided wave could be good indicators of MAZE. However, more rigorous calibration is necessary where inspection direction is carefully devised with respect to the marcelling.

HiCAM↗

NASA NTRS2007

Supportability Technologies for Future Exploration Missions

Future long-duration human exploration missions will be challenged by resupply limitations and mass and volume constraints. Consequently, it will be essential that the logistics footprint required to support these missions be minimized and that capabilities be provided to make them highly autonomous from a logistics perspective. Strategies to achieve these objectives include broad implementation of commonality and standardization at all hardware levels and across all systems, repair of failed hardware at the lowest possible hardware level, and manufacture of structural and mechanical replacement components as needed. Repair at the lowest hardware levels will require the availability of compact, portable systems for diagnosis of failures in electronic systems and verification of system functionality following repair. Rework systems will be required that enable the removal and replacement of microelectronic components with minimal human intervention to minimize skill requirements and training demand for crews. Materials used in the assembly of electronic systems (e.g. solders, fluxes, conformal coatings) must be compatible with the available repair methods and the spacecraft environment. Manufacturing of replacement parts for structural and mechanical applications will require additive manufacturing systems that can generate near-net-shape parts from the range of engineering alloys employed in the spacecraft structure and in the parts utilized in other surface systems. These additive manufacturing processes will need to be supported by real-time non-destructive evaluation during layer-additive processing for on-the-fly quality control. This will provide capabilities for quality control and may serve as an input for closed-loop process control. Additionally, non-destructive methods should be available for material property determination. These nondestructive evaluation processes should be incorporated with the additive manufacturing process - providing an in-process capability to ensure that material deposited during layer-additive processing meets required material property criteria.

Watson, Kevin↗

DOE OSTI2025

Evaluation and Development of Phase Array Ultrasonic Testing (PAUT) System for Additively Manufactured Parts

This research focuses on the application of advanced ultrasonic testing techniques developed by The Phased Array Company (TPAC) for inspecting defects in additive manufacturing (AM) parts. Traditionally, X-ray computed tomography is the standard for inspecting AM components. Although, the long inspection and analysis time, along with relatively high cost make implementation difficult. Thus, an alternative nondestructive evaluation (NDE) approach is necessary to support quality assurance efforts within the field of AM. TPAC is recognized as a leader in ultrasonic testing innovation, deploying sophisticated algorithms such as Total Focusing Method (TFM) and Phased Wave Imaging (PWI) for ultrasonic data processing and interpretation. This work will explore how the TFM and PWI algorithms can assist defect detection within polymer AM parts. The AM field is seeking novel NDE methods to provide support within quality control and assurance efforts. Advanced ultrasonics inspection have the potential to fulfill this need.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Evaluation and Development of Phase Array Ultrasonic Testing (PAUT) System for Additively Manufactured Parts

36 MATERIALS SCIENCE↗

NASA NTRS1993

Enhanced NDE systems

The goal of this contractual effort was to evaluate the Langley narrow-band ultrasonic debond detection method for a factory use configuration. Successful accomplishment requires establishing the robustness of the method, and enhancing it if necessary. It is also desirable to strive for simplicity of implementation, such as attachment to in-place scanning devices planned for nondestructive evaluation (NDE) measurements. The contract was established with three phases for the ultrasonic work: (1) establish the method and robustness of the ultrasonic method; (2) follow up on any questions which arise with respect to the method or its implementation and produce a Phase A design; and (3) fabricate and test the Phase A design. This is a report on Phase 1.

Source record↗

NASA NTRS2004

Sandwich Panels Evaluated With Ultrasonic Spectroscopy

Enhanced, lightweight material systems, such as 17-4PH stainless steel sandwich panels are being developed for use as fan blades and fan containment systems for next-generation engines. The bond strength between the core and face sheets is critical in maintaining the structural integrity of the sandwich structure. To improve the inspection and production of these systems, researchers at the NASA Glenn Research Center are using nondestructive evaluation (NDE) techniques, such as ultrasonic spectroscopy, to evaluate the brazing quality between the face plates and the metallic foam core. The capabilities and limitations of a swept-frequency approach to ultrasonic spectroscopy were evaluated with respect to these sandwich structures. This report discusses results from three regions of a sandwich panel representing different levels of brazing quality between the outer face plates and a metallic foam core. Each region was investigated with ultrasonic spectroscopy. Then, on the basis of the NDE results, three shear specimens sectioned from the sandwich panel to contain each of these regions were mechanically tested.

Cosgriff, Laura M.↗

NASA NTRS2003

Sensing the Tension

Spanning over 4 decades, NASA's bolt tension monitoring technology has benefited automakers, airplane builders, and other major manufacturers that rely on the devices to evaluate the performance of computerized torque wrenches and other assembly line mechanisms. In recent years, the advancement of ultrasonic sensors has drastically eased this process for users, ensuring that proper tension and torque are being applied to bolts and fasteners, with less time needed for data analysis. Langley Research Center s Nondestructive Evaluation Branch is one of the latest NASA programs to incorporate ultrasonic sensors within a bolt tension measurement instrument. As a multi-disciplined research group focused on spacecraft and aerospace transportation safety, one of the branch s many commitments includes transferring problem solutions to industry. In 1998, the branch carried out this obligation in a licensing agreement with Micro Control, Inc., of West Bloomfield, Michigan. Micro Control, an automotive inspection company, obtained the licenses to two Langley patents to provide an improved-but-inexpensive means of ultrasonic tension measurement.

Source record↗

NASA NTRS1985

Holder for Ultrasonic Evaluation of Small-Diameter Tubes

Simple holder eliminates requirement for expensive turntable. Holder works by rotating cylindrical specimens about y-axis. Rotation synchronized with movement of transducer to permit testing without use of turntable. Holder attached to crossmember of scanning bridge with C-clamp. Permits testing of small-diameter tubes rapidly, accurately, and economically. Designed for use with commercially available electromechanical drum-type ultrasonic immersion testing device used for nondestructive evaluation of variety of materials.

Taylor, E. C.↗

NASA NTRS1973

Investigation of solidification in zero-gravity environment; M553 sphere forming experiment. Phase C: Evaluation of Skylab specimens

Results on specimen evaluation and discussion of solidification behavior in each case are reported in the following order: (1) specimen SL-1.6, (2) specimen SL-2.8, (3) specimen SL-2.4, (4) specimen SL-1.10 and (5) specimen SL-1.11. Comparison is made with ground-processed specimens of similar composition, whenever pertinent and meaningful. Among the nondestructive evaluation methods the measurement of sphericity was conducted by micrometric and shadowgraphic techniques. The intricate shape of specimens in some cases appeared difficult to define. In measuring the density, liquid penetration inside cavities that outcrop on the surface was avoided by sealing off these cavities. Among the destructive evaluation methods the use of the Quantimet 720 required particular attention, because of the small difference in contrast between second phases and micropores. With regard to microporosity microvoids in the core of some specimens were so fine that X-ray microradiography had to be used.

Kattamis, T. Z.↗

NASA NTRS1980

Completion of evaluation of manufacturing processes for B/Al composites containing 0.2mm diameter boron fibers

Four fabricators produced a total of 54 B/1100 Al, B/6061 Al, and B/2024 Al panels for evaluation. The 8 ply unidirectional, 45 to 50 volume percent, panels were made using 0.20 mm diameter boron fibers which were obtained from a single supplier. Hot press consolidation was carried out in vacuum except for one set of dry woven tape panels which were hot pressed in air. A single testing contractor conducted nondestructive inspection, metallography, fractography and mechanical property tests. The mechanical property tests included 21 and 260 C tensile tests and 21 C shear tests. Panel quality, as measured by nondestructive evaluation, was generally good as were the 21 C tensile properties. The panels hot pressed in air delaminated in the shear tests. Shear strength values were lower in these panels. But tensile strengths were not affected by the delaminations because of the relation between the tensile loading direction and the delaminations. Composite tensile strength was found to be proportional to the volume percent boron and the aluminum matrix rather than to the tape used or fabrication technique. Suitability of these composites for 260 C service was confirmed by tensile tests.

Moore, T. J.↗