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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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At least 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Ultrasonic Inspection to Quantify Failure Pathologies of Crimped Electrical Connections

Previous work has shown that ultrasonic inspection provides a means of assessing electrical crimp quality that ensures the electrical and mechanical integrity of an initial crimp before the installation process is completed. The amplitude change of a compressional ultrasonic wave propagating at right angles to the wire axis and through the junction of a crimp termination was shown to correlate with the results of destructive pull tests, which is a standard for assessing crimp wire junction quality. Of additional concern are crimps made at high speed assembly lines for wiring harnesses, which are used for critical applications, such as in aircraft. During high-speed assembly it is possible that many faulty crimps go undetected until long after assembly, and fail in service. The position and speed of the crimping jaw become factors as the high-speed crimp is formed. The work presented in this paper is designed to cover the more difficult and more subtle area of high-speed crimps by taking into account the rate change of the measurements. Building on the previous work, we present an analysis methodology, based on transmitted ultrasonic energy and timing of the first received pulse that is shown to correlate to the gauge of the crimp/ferrule combination and the position of the crimping jaw. Results demonstrating the detectability of a number of the crimp failure pathologies, such as missing strands, partially inserted wires and incomplete crimp compression, are presented. The ability of this technique to estimate crimp height, a mechanical measure of crimp quality, is discussed.

Cramer, K. Elliott↗
NASA NTRS2014

Eddy Current Probe for Surface and Sub-Surface Inspection

An eddy current probe includes an excitation coil for coupling to a low-frequency alternating current (AC) source. A magneto-resistive sensor is centrally disposed within and at one end of the excitation coil to thereby define a sensing end of the probe. A tubular flux-focusing lens is disposed between the excitation coil and the magneto-resistive sensor. An excitation wire is spaced apart from the magneto-resistive sensor in a plane that is perpendicular to the sensor's axis of sensitivity and such that, when the sensing end of the eddy current probe is positioned adjacent to the surface of a structure, the excitation wire is disposed between the magneto-resistive sensor and the surface of the structure. The excitation wire is coupled to a high-frequency AC source. The excitation coil and flux-focusing lens can be omitted when only surface inspection is required.

Wincheski, Russell A.↗
NASA NTRS2011

Process Specification for Eddy Current Inspection

This process specification establishes the minimum requirements for eddy current inspection of flat surfaces, fastener holes, threaded fasteners and seamless and welded tubular products made from nonmagnetic alloys such as aluminum and stainless steel.

Koshti, Ajay↗
NASA NTRS2016

Floating Ultrasonic Transducer Inspection System and Method for Nondestructive Evaluation

A method for inspecting a structural sample using ultrasonic energy includes positioning an ultrasonic transducer adjacent to a surface of the sample, and then transmitting ultrasonic energy into the sample. Force pulses are applied to the transducer concurrently with transmission of the ultrasonic energy. A host machine processes ultrasonic return pulses from an ultrasonic pulser/receiver to quantify attenuation of the ultrasonic energy within the sample. The host machine detects a defect in the sample using the quantified level of attenuation. The method may include positioning a dry couplant between an ultrasonic transducer and the surface. A system includes an actuator, an ultrasonic transducer, a dry couplant between the transducer the sample, a scanning device that moves the actuator and transducer, and a measurement system having a pulsed actuator power supply, an ultrasonic pulser/receiver, and a host machine that executes the above method.

Zalameda, Joseph N.↗
NASA NTRS2017

Orion Exploration Flight Test Post-Flight Inspection and Analysis

The multipurpose crew vehicle, Orion, is being designed and built for NASA to handle the rigors of crew launch, sustainment and return from scientific missions beyond Earth orbit. In this role, the Orion vehicle is meant to operate in the space environments like the naturally occurring meteoroid and the artificial orbital debris environments (MMOD) with successful atmospheric reentry at the conclusion of the flight. As a result, Orion's reentry module uses durable porous, ceramic tiles on almost thirty square meters of exposed surfaces to accomplish both of these functions. These durable, non-ablative surfaces maintain their surface profile through atmospheric reentry; thus, they preserve any surface imperfections that occur prior to atmospheric reentry. Furthermore, Orion's launch abort system includes a shroud that protects the thermal protection system while awaiting launch and during ascent. The combination of these design features and a careful pre-flight inspection to identify any manufacturing imperfections results in a high confidence that damage to the thermal protection system identified post-flight is due to the in-flight solid particle environments. These favorable design features of Orion along with the unique flight profile of the first exploration flight test of Orion (EFT-1) have yielded solid particle environment measurements that have never been obtained before this flight.

Miller, J. E.↗
NASA NTRS2016

Post-Test Inspection of NASA's Evolutionary Xenon Thruster Long Duration Test Hardware: Ion Optics

A Long Duration Test (LDT) was initiated in June 2005 as a part of NASA's Evolutionary Xenon Thruster (NEXT) service life validation approach. Testing was voluntarily terminated in February 2014, with the thruster accumulating 51,184 hours of operation, processing 918 kg of xenon propellant, and delivering 35.5 MN-s of total impulse. The post-test inspection objectives for the ion optics were derived from the original NEXT LDT test objectives, such as service life model validation, and expanded to encompass other goals that included verification of in situ measurements, test issue root causes, and past design changes. The ion optics cold grid gap had decreased only by an average of 7% of pretest center grid gap, so efforts to stabilize NEXT grid gap were largely successful. The upstream screen grid surface exhibited a chamfered erosion pattern. Screen grid thicknesses were ≥ 86% of the estimated pretest thickness, indicating that the screen grid has substantial service life remaining. Deposition was found on the screen aperture walls and downstream surfaces that was primarily composed of grid material and back-sputtered carbon, and this deposition likely caused the minor decreases in screen grid ion transparency during the test. Groove depths had eroded through up to 35% of the accelerator grid thickness. Minimum accelerator aperture diameters increased only by about 5-7% of the pretest values and downstream surface diameters increased by about 24-33% of the pretest diameters. These results suggest that increasing the accelerator aperture diameters, improving manufacturing tolerances, and masking down the perforated diameter to 36 cm were successful in reducing the degree of accelerator aperture erosion at larger radii.

Ion Thruster↗
NASA NTRS2017

Investigation of Carbon Fiber Architecture in Braided Composites Using X-Ray CT Inspection

During the fabrication of braided carbon fiber composite materials, process variations occur which affect the fiber architecture. Quantitative measurements of local and global fiber architecture variations are needed to determine the potential effect of process variations on mechanical properties of the cured composite. Although non-destructive inspection via X-ray CT imaging is a promising approach, difficulties in quantitative analysis of the data arise due to the similar densities of the material constituents. In an effort to gain more quantitative information about features related to fiber architecture, methods have been explored to improve the details that can be captured by X-ray CT imaging. Metal-coated fibers and thin veils are used as inserts to extract detailed information about fiber orientations and inter-ply behavior from X-ray CT images.

braided composites↗
NASA NTRS2016

Post-Test Inspection of Nasa's Evolutionary Xenon Thruster Long Duration Test Hardware: Ion Optics

A Long Duration Test (LDT) was initiated in June 2005 as a part of NASAs Evolutionary Xenon Thruster (NEXT) service life validation approach. Testing was voluntarily terminated in February 2014, with the thruster accumulating 51,184 hours of operation, processing 918 kg of xenon propellant, and delivering 35.5 MN-s of total impulse. This presentation will present the post-test inspection results to date for the thrusters ion optics.

Ion Engine↗
NASA NTRS2016

Post-Test Inspection of NASA's Evolutionary Xenon Thruster Long-Duration Test Hardware: Discharge Chamber

NASAs Evolutionary Xenon Thruster (NEXT) Long-Duration Test (LDT) is part of the comprehensive service life assessment of the NEXT thruster. The test was voluntarily terminated in April 2014 after accumulating 51,184 hours of high voltage operation, processing 918 kg of xenon, and delivering 35.5 MN-s of total impulse. This presentation covers the post-test inspection of the thruster hardware, in particular of the discharge chamber and other miscellaneous components such as propellant isolators and electrical cabling.

Ion Thrusters↗
NASA NTRS2017

Autonomous Inspection of Electrical Transmission Structures with Airborne UV Sensors - NASA Report on Dominion Virginia Power Flights of November 2016

The report details test and measurement flights to demonstrate autonomous UAV inspection of high voltage electrical transmission structures. A UAV built with commercial, off-the-shelf hardware and software, supplemented with custom sensor logging software, measured ultraviolet emissions from a test generator placed on a low-altitude substation and a medium-altitude switching tower. Since corona discharge precedes catastrophic electrical faults on high-voltage structures, detection and geolocation of ultraviolet emissions is needed to develop a UAV-based self-diagnosing power grid. Signal readings from an onboard ultraviolet sensor were validated during flight with a commercial corona camera. Geolocation was accomplished with onboard GPS; the UAV position was logged to a local ground station and transmitted in real time to a NASA server for tracking in the national airspace.

Moore, Andrew J.↗
NASA NTRS2018

Autonomous Inspection of Electrical Transmission Structures with Airborne UV Sensors and Automated Air Traffic Management

This report details test and measurement flights to demonstrate autonomous UAV (Unmanned Aerial Vehicle) inspection of high-voltage electrical transmission structures. A UAV built with commercial, off-the-shelf hardware and software, supplemented with custom sensors and logging software, measured ultraviolet (UV) emissions from a test generator placed on a low-altitude substation and a medium-altitude switching tower. Since corona discharge precedes catastrophic electrical faults on high-voltage structures, detection and geolocation of ultraviolet emissions is needed to develop a UAV-based self-diagnosing power grid. Signal readings from an onboard ultraviolet sensor were validated during flight with a commercial corona camera. Geolocation was accomplished with onboard GPS; the UAV position was logged to a local ground station and transmitted in real time to a NASA server for tracking in the national airspace. The method has practicality and relevance but not adequacy; either improved UAV position determination technology or increased sensor range is needed to enable broad deployment of this method.

Moore, Andrew J.↗
NASA NTRS2020

NASA Fastener Procurement, Receiving Inspection, and Storage Practices for NASA Mission Hardware

This document establishes minimum requirements for supply chain risk management, procurement, receiving inspection, testing, traceability management, and storage practices for fasteners used in NASA mission hardware. This document does not contain fastener requirements pertaining to design or design analysis; design and design analysis requirements are contained in NASA-STD-5020, Requirements for Threaded Fastening Systems in Spaceflight Hardware.

Safety and Mission Assurance↗
NASA NTRSDate not supplied

Autonomous Spacecraft Inspection with Free-Flying Drones

This paper describes a proof-of-concept mission demonstrating a multi-agent system performing visual inspection of damage sustained by a spacecraft. Free-flying satellites, simulated by unmanned aerial vehicles (UAVs), autonomously fly around a mock space module maximizing the search space for damage detection. The free-flyers are responsible for independently coordinating their flights to avoid collision with the space module and each other, while executing mission tasks. Damage analysis on the surface of the mock space module is performed in real-time using video from each free-flyer. Three-dimensional modeling is deployed offline to supplement and improve damage detection. This approach demonstrates the feasibility of deploying real space systems for damage detection, where 2D analysis can quickly determine region of interest and 3D visualization can produce a human-navigable virtual environment with depth perspective for further investigation.

unmanned aerial vehicle (UAV)↗
NASA NTRS2021

Post-test Inspection of NASA’s Evolutionary Xenon Thruster Long Duration Test Hardware: Ion Optics

A Long Duration Test (LDT) was initiated in June 2005 as a part of NASA’s Evolutionary Xenon Thruster (NEXT) service life validation approach. Testing was voluntarily terminated in February 2014, with the thruster accumulating 51,184 hours of operation, processing 918 kg of xenon propellant, and delivering 35.5 MN-s of total impulse. The post-test inspection objectives for the ion optics were derived from the original NEXT LDT test objectives, such as service life model validation, and expanded to encompass other goals that included verification of in situ measurements, test issue root causes, and past design changes. The ion optics cold grid gap had decreased only by an average of 7% of pretest center grid gap, so efforts to stabilize NEXT grid gap were largely successful. The upstream screen grid surface exhibited a chamfered erosion pattern. Screen grid thicknesses were ≥ 86% of the estimated pretest thickness, indicating that the screen grid has substantial service life remaining. Deposition was found on the screen aperture walls and downstream surfaces that was primarily composed of grid material and back-sputtered carbon, and this deposition likely caused the minor decreases in screen grid ion transparency during the test. Groove depths had eroded through up to 35% of the accelerator grid thickness. Minimum accelerator aperture diameters increased only by about 5-7% of the pretest values and downstream surface diameters increased by about 24-33% of the pretest diameters. These results suggest that increasing the accelerator aperture diameters, improving manufacturing tolerances, and masking down the perforated diameter to 36 cm were successful in reducing the degree of accelerator aperture erosion at larger radii.

George C. Soulas↗
NASA NTRSDate not supplied

Short Circuiting the Controller –Missteps in Maintenance and Inspection of Process and Wiring in STS-93

During the launch of the Chandra X-Ray Observatory in 1999, an in-flight anomaly occurred a few seconds after liftoff. A power fluctuation caused two Main Engine controllers to drop offline. Fortunately, due to redundancy, the Space Shuttle Columbia was able to successfully reach orbit and avoid an abort. After the successful deployment of Chandra and the safe return of the crew, in-vestigation revealed that the controller failure was due to a wire short in the pay-load bay. It was suspected that the Kapton insulation on the wire rubbed off against a burred screw head, the result of overtightening of the screw during a maintenance event 4 to 5 years prior to the STS-93 mission. Vibrations led the abraded wire to short during flight. The Space Shuttle Program was grounded for 4 months while a program-wide inspection and wire chafing mitigation effort of all orbiter wiring ensued.

Kristy S Yun↗
NASA NTRS2021

Thermal Inspection of a Composite Fuselage Section Using theMethod of Proper Generalized Decomposition

Proper Generalized Decomposition (PGD) is a reduced order modeling technique for the simulation of physical systems whose governing equations depend on boundary conditions, initial conditions, material properties, and geometric parameters. It uses separated representations of system covariates combined with an iterative approximation method known as successive enrichment in order to compute an accurate parameter-dependent approximation to the full governing equations. PGD can also be used as an alternative to the Singular Value Decomposition (SVD) of a matrix and therefore as an alternative to PCA thermography. In this paper PGD was used to analyze data derived from the inspection of a composite fuselage forward section using flash thermography, and the results were compared against the standard PCA approach.

Nondestructive Evaluation↗
NASA NTRS2021

Large-Scale CT Inspection of Feed-Through EMI Filters for Space Application

A type of Feed-Through Electromagnetic Interference (EMI) Filter incorporating two discoidal (ring-shaped) capacitors was selected for use in the Europa Clipper spacecraft propulsion systems. Parts reliability specialists were aware of historical problems with the attach materials used to provide mechanical support and electrical contact within these devices, so therefore a screening was desired to ensure the longevity and ruggedness of units intended for the space environment. CT X-ray, a technology which has become more widely available thanks to the compelling depth of information it offers, was selected as the inspection method of choice.

Bescup, John C↗
NASA NTRS2024

ENLIGHTEN: Electrical Network Line Inspection Guided by High-Speed Technology & Electromagnetic Navigation

Natural disasters are a major cause of power outages, primarily due to their damage to power line infrastructure. As a result, the current state of power maintenance, with a heavy reliance on manual labor, is in trouble. Its lack of speed and autonomy must be addressed to ensure power security for households and institutions worldwide. This innovative approach explores how High-Speed Unmanned Aerial Vehicle (HSUAV) technology can inspect power line infrastructure rapidly in response to natural disaster scenarios. The HSUAV technology will be accompanied by enhanced sensory equipment including light detection and ranging (LiDAR), thermal imaging, and electromagnetic field (EMF) navigation. It would also be supplemented by innovative forms of machine learning models and recharging systems to efficiently detect anomalies in power line infrastructure. The proposed system, ENLIGHTEN, can help restore power in affected communities after a devastating natural disaster, greatly improving relief efforts. In the future, ENLIGHTEN can be expanded beyond the United States and shared worldwide, effectively mitigating the consequences on a larger scale.

UAV systems, Power line management, Natural disast↗