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Thermography is excellent at rapid detection of delaminations in composite sandwich structure. Interpretation of the results can be difficult – Especially for complex geometries. The use of complementary techniques such as X-ray CT or ultrasound may be necessary to get the complete picture.
Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA?s Advanced Composites Project, a public-private partnership between government, universities and industry, seeks to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites is one of the three focused research areas of the project. One deliverable of the project is to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publically available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate polymer matrix composite (PMC) structures. The Handbook will reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. The Handbook will include an NDE Guidance Matrix that provides an applicability rating for NDE techniques as they apply to given flaw types. NDE techniques will include, but is not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types will include, but are not limited to porosity, delamination, voids, AFP defects and impact damage. The Handbook will contain details that support the applicability rating including, but not limited to, specimen details, inspection parameters, data analysis techniques, inspection efficiency (speed & cost), and limitations. This presentation will describe key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members.
The primary focus of the nondestructive evaluation (NDE) effort at Langley Research Center (LaRC) is to pioneer advances in NDE and structural health monitoring (SHM) through fundamental scientific research, technology development, and transferring these to the scientific and aerospace communities. This research supports a variety of NASA missions in space operations, exploration and aeronautics. The work presented will focus on the development of advanced inspection systems to detect critical flaws in both metallic and non-metallic materials and structures for aerospace applications. The emphasis is on increasing the performance of inspection systems to provide defect detection and quantitative characterization of the material state. LaRC NDE utilizes expertise in computational ultrasonic, thermal and eddy current simulations to reduce measured responses to size and locations of flaws, establish technique limitations and optimize performance. This presentation will highlight research into five strategic areas: (1) The development of novel solutions using state-of-the-art NDE technologies such as eddy current, ultrasound, thermography and x-ray computed tomography; (2) Research in the development of unique NDE technologies such as terahertz, wavefield imaging and nonlinear ultrasound; (3) The application of both computational and analytic models to NDE problems; (4) The development of advanced analytic methods to interpret large complex data sets; and (5) Advanced methods of applying and interrogating sensors for structural health monitoring.
Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA’s Advanced Composites Project, a public-private partnership between government, universities and industry, sought to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites was one of the three focused research areas of the project. One deliverable of the project was to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publicly available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate carbon fiber reinforced polymer composite (CFRP) structures. The Handbook seeks to reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. NDE techniques include, but are not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types include, but are not limited to porosity, delamination, voids, AFP defects and impact damage. The Handbook contains details such as inspection parameters, data analysis techniques, inspection efficiency (speed & cost), and limitations. This presentation will describe key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members. Availability of the fabricated NDE standards as well as the raw data collected on the standards by the Consortium members to the NDE community is discussed.
The primary focus of the nondestructive evaluation (NDE) effort at Langley Research Center (LaRC) is to pioneer advances in NDE and structural health monitoring (SHM) through fundamental scientific research, technology development, and transferring these to the scientific and aerospace communities. This research supports a variety of NASA missions in space operations, exploration and aeronautics. The work presented will focus on the development of advanced inspection systems to detect critical flaws in both metallic and non-metallic materials and structures for aerospace applications. The emphasis is on increasing the performance of inspection systems to provide defect detection and quantitative characterization of the material state. LaRC NDE utilizes expertise in computational ultrasonic, thermal and eddy current simulations to reduce measured responses to size and locations of flaws, establish technique limitations and optimize performance. This presentation will highlight research into five strategic areas: (1) The development of novel solutions using state-of-the-art NDE technologies such as eddy current, ultrasound, thermography and x-ray computed tomography; (2) Research in the development of unique NDE technologies such as terahertz, wavefield imaging and nonlinear ultrasound; (3) The application of both computational and analytic models to NDE problems; (4) The development of advanced analytic methods to interpret large complex data sets; and (5) Advanced methods of applying and interrogating sensors for structural health monitoring.
Historically, there have been a limited number of studies involving Transitional Shock-Wave/Boundary-Layer Interactions (XSWBLI) in hypersonic flows, the majority of which have been performed at Mach Numbers of 7.5 and below. Additionally, there have been even fewer such experiments which incorporate non-intrusive and optical diagnostics. NASA Langley Research Center (NASA LaRC), in collaboration with The University of Texas at San Antonio (UTSA) and The University of Tennessee Space Institute (UTSI), is currently planning and preparing for a series of experimental aerodynamic tests using the NASA LaRC 31-inch Mach 10 Air Tunnel. The experiments will primarily focus on studying the dynamics of Shock-Wave/Boundary-Layer Interactions (SWBLI) in the presence of transition (XSWBLI) and turbulence (SWTBLI) on a large, flat plate model at a freestream Mach number of 10. Besides continued interest in understanding the flow at high Mach numbers, executing such tests at Mach 10 avoids some known concerns and will aid in solving new problems. XSWBLI are a highly unsteady phenomena and the generation of XSWBLI at lower Mach numbers can prove to be a significant challenge. This concern will be somewhat mitigated in the Mach 10 flow, as boundary layers become increasingly stabilized, but some difficulty in achieving transition is still expected. Modelling SWBLI in the presence of transitional and turbulent boundary layers has also proven to be difficult, so a high-Mach number experiment which applies non-intrusive and optical diagnostics will aid in solving a unique problem as well as advancing the understanding and characterization of an aerodynamic surface at Mach 10.The NASA LaRC 31-inch Wind Tunnel incorporates a test section having a cross-section of 31-inches × 31-inches and provides optical access to the test section via three (3) ultra-violet (UV) transmitting windows on the top, side, and bottom. The Mach 10 operating conditions will consist of pressures (P0) ranging from 2.4 to 10MPa (348 to 1,450 psi) at a temperature (T0) of 1,000 K (1,800 °R). The NASA LaRC 31-inch wind tunnel will deliver 1-minute blow-down runs, of which 30-45 seconds will be consumed to reach the aforementioned test conditions. The pump down time between runs will be approximately 45-60 minutes, which will provide for 6-10 test runs per day over the course of a weeklong entry. The proposed flat plate model will be constructed of stainless steel with geometry consisting of a10-inch × 30-inch upper surface and a 2-inch thickness. The model will be designed to support multiple leading-edge inserts in order to examine blunt, round, and sharp leading edges at Mach 10. Adjustments will be made to manage boundary layer thickness as well as the strength and size of the shock interaction region for each test. Measurements and diagnostics will be performed though high-speed Schlieren, on-body high-speed pressure transducers, IR thermography, and oil flow visualization. Hypersonic vehicle applications have and will continue to emerge at the forefront of aerospace. The NASA-UTSA-UTSI team realizes the value of characterizing SWBLI, XSWBLI, and SWTBLI behaviors well beyond single-digit hypersonic Mach numbers. As hypersonic vehicle speed capabilities continue to increase, measurement and diagnostic methods for Mach numbers of 10 and beyond will provide the foundation for a firm understanding of flow field behavior which will directly influence the advancement of technologies towards the design and manufacturing of high-speed aerodynamic surfaces, controls, thermal protection systems, acoustic treatments, and structural components. The use of non-intrusive and optical diagnostic methods in such experimentation is pivotal in developing the visualization and empirical data necessary to advance the aforementioned technology areas.
Shock-wave boundary-layer interactions (SWBLI) pose unique challenges for the slender airframes and sharp control surfaces characteristic of high-speed airbreathing aircraft. Spikes in pressure and thermal loading have been shown to occur in SWBLI regions; thus, predicting their location and behavior proves critical for assuring aircraft structural integrity and fatigue resilience. SWBLIs frequently lead to severe turbulent boundary-layer separation and corresponding unsteady motions characterized by a wide range of frequencies. Low-frequency motion has been shown to couple with the structure of a compliant panel, and turbulent boundary layers thus present a particular danger for thin control surfaces. Previous studies have shown that the thermal loading on a compliant panel in a ramp-induced SWBLI may have a signi cant impact on the panel vibrations. A multitude of studies has investigated the heating on rigid structures, but a charactrization of the heating effects on compliant structures is necessary to fully understand the fluid-thermal-structural interactions (FTSI) occurring in ramp-induced SWBLIs. This studuses infrared thermography and high-frequency Kulite pressure transducers to examine the heating loads on rigid and compliant ramps at various angles and flow conditions at Mach 6.
The middle-wavelength infrared (MWIR) waveband is considered the “spectral fingerprint”for many chemical species. MWIR: 3 –10 μm wavelength range. MWIR imaging devices are important for multispectral imaging, thermography, chemical spectroscopy, surveillance, automotive safety, and astronomy. Tunable optical properties are desired to increase the amount of information that is detectable. Ge2Sb2Te5(GST) is a chalcogenide phase change material (PCM) that has the potential to be used as a compact, solid-state, fast-switching tunable optical filter.
The effects of fin-leading-edge radius and sweep angle on peak heating rates due to shock-shock interactions were investigated in the NASA Langley Research Center 20-Inch Mach 6 Air Tunnel. The fin model leading edges, which represent cylindrical leading edges or struts on hypersonic vehicles, were varied from 0.25 inches to 0.75 inches in radius. A 9° wedge generated a planar oblique shock at 16.7° to the flow that intersected the fin bow shock, producing a shock-shock interaction that impinged on the fin leading edge. The fin angle of attack was varied from 0° (normal to the free-stream) to 15° and 25° swept forward. Global temperature data were obtained from the surface of the fused silica fins through phosphor thermography. Metal oil flow models with the same geometries as the fused silica models were used to visualize the streamline patterns for each angle of attack. High-speed zoom-schlieren videos were recorded to show the features and temporal unsteadiness of the shock-shock interactions. The temperature data were analyzed using one-dimensional semi-infinite as well as one- and two-dimensional finite-volume methods to determine the proper heat transfer analysis approach to minimize errors from lateral heat conduction due to the presence of strong surface temperature gradients induced by the shock interactions. The general trends in the leading-edge heat transfer behavior were similar for the three shock-shock interactions, respectively, between the test articles with varying leading-edge radius. The dimensional peak heat transfer coefficient augmentation increased with decreasing leading-edge radius. The dimensional peak heat transfer output from the two-dimensional code was about 20% higher than the value from a standard, semi-infinite one-dimensional method.
NASA, commercial, medical, and defense applications such as Earth observation systems, astronomy, weather monitoring, thermal mapping, thermography, missile tracking, and night vision aids, etc. require high performance large format long wavelength infrared (LWIR) detector arrays in the range of 8-16 µm.
The first two phases of the NASA Juncture Flow experiment were carried out on a DLR-F6 swept-wing model and were designed to provide “CFD validation-quality” data toward the assessment and improvement of existing CFD turbulence models in predicting onset and extent of three-dimensional separated flow near the wing-juncture trailing-edge region. The next phase of experiments will involve an NACA 0015-based swept wing, as prior risk reduction experiments had indicated that this wing shape resulted in reduced separation near the juncture region than the DLR-F6 wing, thus providing a better option to evaluate the ability of CFD models to predict incipient turbulent separation. The NACA 0015 measurements will also include IR thermography to infer the variation of transition front with respect to an increasing angle of attack. The primary objective of this work is to computationally make a preliminary assessment of the transition front on both surfaces of the NACA 0015 wing at a crank-chord-based Reynolds number of 2.4 x 106 for four different angles of attack, (0°, 2.5°, 5°, and 7.5°) and to determine the dominant mechanisms responsible for transition. This assessment includes both RANS-based transition models from NASA’s OVERFLOW 2.3b flow solver and linear parabolized stability equations (PSE) stability analysis based on the Langley Stability and Transition Analysis code, LASTRAC. Linear PSE results indicate that the upper surface of the wing is dominated by Tollmien- Schlichting (TS) instabilities, and that the laminar flow region shrinks from about 50% chord to a very small region just downstream of the attachment line as the angle of attack is increased from 0° to 7.5°. Consequently, the transition fronts predicted by the Spalart- Allmaras-based amplification factor transport (AFT-2017b) equation model (which accounts for the TS instabilities alone) and the Menter’s shear-stress transport equation (SST2003)- based Langtry-Menter transition model with ability to account for both TS and crossflow effects (LM2015) compare well with those predicted using linear PSE. On the lower surface of the wing, stationary crossflow (CF) instabilities begin to appear on the inboard portion of the wing in addition to the TS-instabilities for the larger angles of attack (5° and 7.5°), further reducing the laminar flow extent within the inboard region. The LM2015 model that accounts for CF effects is able to replicate this trend but appears to predict a slightly earlier transition. The outcome of this effort will inform the experiment and, when the actual experimental data become available, provide further opportunity to assess and improve the various transition models.
The first two phases of the NASA Juncture Flow experiment were carried out on a DLR-F6 swept-wing model and were designed to provide “CFD validation-quality” data toward the assessment and improvement of existing CFD turbulence models in predicting onset and extent of three-dimensional separated flow near the wing-juncture trailing-edge region. The next phase of experiments will involve an NACA 0015-based swept wing, as prior risk reduction experiments had indicated that this wing shape resulted in reduced separation near the juncture region than the DLR-F6 wing, thus providing a better option to evaluate the ability of CFD models to predict incipient turbulent separation. The NACA 0015 measurements will also include IR thermography to infer the variation of transition front with respect to an increasing angle of attack. The primary objective of this work is to computationally make a preliminary assessment of the transition front on both surfaces of the NACA 0015 wing at a crank-chord-based Reynolds number of 2.4 x 106 for four different angles of attack, (0°, 2.5°, 5°, and 7.5°) and to determine the dominant mechanisms responsible for transition. This assessment includes both RANS-based transition models from NASA’s OVERFLOW 2.3b flow solver and linear parabolized stability equations (PSE) stability analysis based on the Langley Stability and Transition Analysis code, LASTRAC. Linear PSE results indicate that the upper surface of the wing is dominated by Tollmien- Schlichting (TS) instabilities, and that the laminar flow region shrinks from about 50% chord to a very small region just downstream of the attachment line as the angle of attack is increased from 0° to 7.5°. Consequently, the transition fronts predicted by the Spalart- Allmaras-based amplification factor transport (AFT-2017b) equation model (which accounts for the TS instabilities alone) and the Menter’s shear-stress transport equation (SST2003)- based Langtry-Menter transition model with ability to account for both TS and crossflow effects (LM2015) compare well with those predicted using linear PSE. On the lower surface of the wing, stationary crossflow (CF) instabilities begin to appear on the inboard portion of the wing in addition to the TS-instabilities for the larger angles of attack (5° and 7.5°), further reducing the laminar flow extent within the inboard region. The LM2015 model that accounts for CF effects is able to replicate this trend but appears to predict a slightly earlier transition. The outcome of this effort will inform the experiment and, when the actual experimental data become available, provide further opportunity to assess and improve the various transition models.
Advanced NDE and SHM techniques are critical for ensuring the reliability and safety of NASA launch vehicles and spacecraft. NDE techniques such as infrared thermography, THz imaging, x-ray computed tomography and backscatter x-ray are used to detect indications of damage in spacecraft components and structures. Additionally, sensor and measurement systems are integrated into spacecraft to provide SHM to detect damaging events that occur during flight such as debris impacts during launch and assent or from micrometeoroid and orbital debris, or excessive loading due to anomalous flight conditions. A number of examples will be provided of how these NDE and SHM techniques have been applied to resolve safety critical inspection concerns for the Space Shuttle, International Space Station (ISS), and a variety of launch vehicles and unmanned spacecraft.
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.
NASA Langley’s hypersonic wind tunnels are heavily leveraged for planetary missions. The data collection method in these tunnels is thermography, and surface temperature measurements of the model surface are collected and reduced to produce surface heating data, as seen in Fig 1. However, during model injection, no temperature data are collected, and thus conventional, integral heat transfer methods cannot be used to solve for surface heating. A method was developed in the 1990’s to reduce this data despite the data gap, known as the step approximation method. The method assumes that the film coefficient behaves as a step function, the model is semi-infinite, and thermal properties are constant. With these simplifying assumptions, a Laplace transform can be performed to result in an equation that takes the initial temperature of the model and a temperature at some point in time to back out the film coefficient at that time. This is the method that is used in the current thermographic data reduction software, IHEAT. While computationally light-weight, the step approximation has several issues associated with it. The time-history of temperature is not accounted for, which is vital as heat transfer is an integral process. Additionally, the required semi-infinite assumption is unnecessary and might be violated during runtime. Thermal variation of material properties can have a sizeable impact on heating results and are not modeled by the method. This method also takes multiple seconds to “collapse” to a steady state, which is undesirable from both a facility and data reduction standpoint. The method is also very sensitive to the “effective time” approximation, an approximation of when heating instantaneously starts (which is a nonphysical simplification), and a small variation in this value can result in an error in heating results.
In support of flight programs, multiple wind tunnel entries were conducted on reentry vehicle configurations to investigate blunt body aeroheating environments. Blunt body block thermal protection system (TPS) roughness, the Low-Earth Orbit Flight Test of an Inflatable Decelerator aeroshell scalloping, and a woven TPS all were tested to determine the effects of those parameters on increased surface heating to the vehicle. Commercial Crew Program studies also utilized the speed and ease of testing in the LAL to analyze parametric databases of low-earth reentry configurations, like the Boeing CST-100, and vehicles designed to travel to the moon or Mars, such as the SpaceX Starship. LAL wind tunnel investigations also supported several DoD and AFRL flight projects, such as HIFiRE 6 and BOLT. External customers leveraged the LAL testing capability to advance their research programs, including UPSTAR, RocketLab, and Lawrence Livermore National Laboratory. Academia groups benefitted from the inexpensive cost to test in the tunnels for many university collaborations, such as studies conducted in partnership with the University of Maryland on a flat plate, using a pressure rake and investigating fluid structure interactions. Multiple studies in collaboration with Purdue considered boundary layer transition on various cone configurations. Another study was conducted using a cone with shaped roughness elements borrowed from the Arnold Engineering Development Complex. Internal testing included studies using a phosphor thermography system that can measure higher temperatures than the current LAL phosphor capability and a characterization study of the noise in the wind tunnel flow. The breadth of testing across research and commercial paradigms, both internal and external to NASA, different configurations, a variety of test techniques and aerodynamic and aerothermal environments will be discussed in this overview presentation of the recent work conducted in the LAL.
A simple method for detecting boundary-layer transition using only mean static pressure port data is presented. The method can be applied to most existing models with pressure taps, and only requires that a fine angle-of-attack sweep be performed. A small but abrupt change in the static pressure is visible when the transition front passes over the pressure tap. Results from a recent Juncture Flow test entry are used to illustrate the technique. Infrared thermography measurements of the transition front compare very well to the transition locations obtained from the static pressure ports. Some differences in behavior occur depending on the dominant transition mechanism. While the technique is somewhat qualitative, it can be an excellent tool for estimating the transition location when other tools are not readily available. Given the simplicity of the technique, and the fact that most wind-tunnel models are already designed with numerous static pressure taps, this method can be applied with very little overhead.
An experimental investigation of boundary-layer transition and convective surface heating on wind tunnel models that simulated aeroshells comprised of multiple blocks of thermal protection system (TPS) material has been performed. Two representative entry vehicle geometries, a sphere-cone aeroshell and a sphere-cone aeroshell, were considered. Multiple cast ceramic models of each geometry were fabricated with varying fence heights or gap depths to represent gap fillers that either protrude above, or are recessed below, the TPS blocks due to differential ablation during reentry. Wind tunnel testing was performed at Mach 6 over a range of Reynolds numbers sufficient to produce laminar, transitional, and turbulent flow. Convective surface heating and boundary-layer transition onset data were obtained using global phosphor thermography. The experimental heating data are presented herein, as are comparisons to laminar and turbulent smooth-wall heat transfer distributions from computational flow field simulations.