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NASA NTRS2016

Combining Passive Thermography and Acoustic Emission for Large Area Fatigue Damage Growth Assessment of a Composite Structure

Passive thermography and acoustic emission data were obtained for improved real time damage detection during fatigue loading. A strong positive correlation was demonstrated between acoustic energy event location and thermal heating, especially if the structure under load was nearing ultimate failure. An image processing routine was developed to map the acoustic emission data onto the thermal imagery. This required removing optical barrel distortion and angular rotation from the thermal data. The acoustic emission data were then mapped onto thermal data, revealing the cluster of acoustic emission event locations around the thermal signatures of interest. By combining both techniques, progression of damage growth is confirmed and areas of failure are identified. This technology provides improved real time inspections of advanced composite structures during fatigue testing.Keywords: Thermal nondestructive evaluation, fatigue damage detection, aerospace composite inspection, acoustic emission, passive thermography

Zalameda, Joseph N.↗

NASA NTRS2018

Real Time Detection of Damage During Quasi-Static Loading of a Single Stringer Panel Using Passive Thermography

Real time nondestructive evaluation is required for composites load testing. The early detection and measurement of damage progression is important to understand failure modes. A single stringer panel was subjected to quasi-static loading to induce deformation which can result in the formation of delamination damage between the stiffener flange and skin. Passive thermography was used to detect damage in real time as a function of the applied load. The loading was stopped when damage growth was detected. Of particular interest was the early detection of damage formation which can be challenging, as compared to cyclic fatigue loading. Passive thermography data were acquired and processed in real time and revealed damaged areas due to heating from fiber breakage and delamination formation. The processed thermal imagery was also compared to acoustic emission and ultrasound data.

Zalameda, Joseph N.↗

NASA NTRSDate not supplied

Delamination Depth Imaging for Quasi-Static and Fatigue Load Testing Using Passive Thermography

Passive thermography is used to monitor small increases in temperature resulting from delamination damage formation in composite hat-stiffened panels during both quasi-static and fatigue loading. It has been observed that rapid damage formation produces heating. This is composed of two heat generation components. The first component is an instantaneous response due to an irreversible thermoelastic strain release. The second component is mechanical heating, at the interface of failure, due to fracture damage. This produces a transient rise in temperature as the heat diffuses to the surface. The first component defines the thermal start time for the transient response. A one-dimensional thermal model is fitted to the data pixel by pixel, to produce imagery of the damage depth. The results are compared to ultrasonic and X-ray CT data.

Passive thermography↗

NASA NTRSDate not supplied

Characterization of Composite Damage Using Passive Thermography

Passive thermography is used to monitor small increases in temperature on a composite structure during loading. A rise in temperature can be attributed to damage formation due to matrix cracking and fiber breaks. An infrared camera allows for imaging the damage location, size, and shape. Recently, a technique has been developed to estimate the depth of the damage in a composite hat-stiffened panel during quasi-static loading. This technique is based on two heat generation components. The first component is an instantaneous thermoelastic response due to a strain release. The second component is mechanical heating, at the interface of failure, due to fracture damage. This second component produces a transient rise in temperature that is a function of the damage depth and thermal diffusivity. The first component defines the thermal start time for the transient response. A one-dimensional thermal model is used to determine the damage depth for a known thermal diffusivity. The results are compared to ultrasonic and X-ray CT data and show good agreement for damage depth.

Thermal nondestructive evaluation↗

NASA NTRSDate not supplied

Progress on Quantitative Infrared Thermography at the NASA Langley Aerothermodynamic Laboratory

A quantitative infrared thermography technique is being developed for accurate and high-resolution measurements of surface temperature and heat flux in the hypersonic wind tunnels at NASA Langley Research Center. A hemisphere test campaign was carried out in the Langley Aerothermodynamic Laboratory 20-Inch Mach 6 Air Tunnel to assess the current performance of the technique and to identify remaining challenges. Measurements were obtained for three different model materials over a range of freestream Reynolds numbers. The raw infrared images were converted to temperature via a radiometric calibration of the camera sensor. Corrections were made for losses due to test article emissivity and window transmissivity. A preliminary uncertainty analysis yielded an estimated accuracy within 4 K at moderate viewing angles, similar to that of a standard thermocouple. Surface heat flux was obtained from the measured surface temperatures via a finite-difference solution of the one-dimensional heat equation that modeled thermal variation of the material properties. Comparisons of the measured heating to both computational and theoretical predictions demonstrated agreement within the expected uncertainty of the technique. The heat transfer measurement near the stagnation point was found to be highly sensitive to the test article emissivity, which establishes the need for improved characterization of the wind tunnel model materials for high temperature applications.

infrared thermography↗

NASA NTRS1977

Use of aerial thermography in Canadian energy conservation programs

Recent developments in the use of aerial thermography in energy conservation programs within Canada were summarized. Following a brief review of studies conducted during the last three years, methodologies of data acquisition, processing, analysis and interpretation was discussed. Examples of results from an industrial oriented project were presented and recommendations for future basic work were outlined.

Cihlar, J.↗

NASA NTRS1980

The evaluation of evaporation by infrared thermography: A critical analysis of the measurements on the Crau test site

Evapotranspiration was calculated for both the dry and irrigated zone by four methods which were compared with the energy balance method serving as a reference. Two methods did not involve the surface temperature. They are ETR(n) = R(n), liable to be valid under wet conditions and ET(eq) = (delta/delta + gamma) R(n) i.e, the first term of Penman's equation, adapted to moderately dry conditions. The methods using surface temperature were the combined energy balance aerodynamic approach and a simplified approach proposed by Jackson et al. Tests show the surface temperature methods give relatively satisfactory results both in the dry and wet zone, with a precision of 10% to 15% compared with the reference method. As was to be expected, ET(eq) gave satisfactory results only in the dry zone and ET(Rn) in the irrigated zone. Thermography increased the precision in the estimate of ET relative to the most suitable classical method by 5% to 8% and is equally suitable for both dry and wet conditions. The Jackson method does not require extensive ground measurements and the evaluation of the surface roughness.

Seguin, B.↗

NASA NTRS1982

Uses of infrared thermography in the low-cost solar array program

The Jet Propulsion Laboratory has used infrared thermography extensively in the Low-Cost Solar Array (LSA) photovoltaics program. A two-dimensional scanning infrared radiometer has been used to make field inspections of large free-standing photovoltaic arrays and smaller demonstration sites consisting of integrally mounted rooftop systems. These field inspections have proven especially valuable in the research and early development phases of the program, since certain types of module design flaws and environmental degradation manifest themselves in unique thermal patterns. The infrared camera was also used extensively in a series of laboratory tests on photovoltaic cells to obtain peak cell temperatures and thermal patterns during off-design operating conditions. The infrared field inspections and the laboratory experiments are discussed, and sample results are presented.

Glazer, S. D.↗

NASA NTRS1991

Surface temperature/heat transfer measurement using a quantitative phosphor thermography system

A relative-intensity phosphor thermography technique developed for surface heating studies in hypersonic wind tunnels is described. A direct relationship between relative emission intensity and phosphor temperature is used for quantitative surface temperature measurements in time. The technique provides global surface temperature-time histories using a 3-CCD (Charge Coupled Device) video camera and digital recording system. A current history of technique development at Langley is discussed. Latest developments include a phosphor mixture for a greater range of temperature sensitivity and use of castable ceramics for inexpensive test models. A method of calculating surface heat-transfer from thermal image data in blowdown wind tunnels is included in an appendix, with an analysis of material thermal heat-transfer properties. Results from tests in the Langley 31-Inch Mach 10 Tunnel are presented for a ceramic orbiter configuration and a four-inch diameter hemisphere model. Data include windward heating for bow-shock/wing-shock interactions on the orbiter wing surface, and a comparison with prediction for hemisphere heating distribution.

Buck, G. M.↗

NASA NTRS1991

New applications of liquid-crystal thermography in rotating turbomachinery heat transfer research

Two new liquid-crystal thermography techniques developed for use in rotating heat transfer experiments are described. In one experiment steady-state heat transfer data were obtained on the exterior surface of rotating turbine airfoil models. In the second study a transient technique was employed to obtain interior-surface heat transfer data in a rotating turbine blade coolant passage model. Sample data are presented in the form of photographs of the liquid-crystal temperature patterns and as contour maps and distributions of heat transfer on the rotor and coolant passage surfaces.

Blair, M. F.↗

NASA NTRS1997

Endoscopic Shearography and Thermography Methods for Nondestructive Evaluation of Lined Pressure Vessels

The goal of this research effort was the development of methods for shearographic and thermographic inspection of coatings, bonds, or laminates inside rocket fuel or oxidizer tanks, fuel lines, and other closed structures. The endoscopic methods allow imaging and inspection inside cavities that are traditionally inaccessible with shearography or thermography cameras. The techniques are demonstrated and suggestions for practical application are made in this report. Drawings of the experimental setups, detailed procedures, and experimental data are included.

Russell, S. S.↗

NASA NTRS1998

Finite Element Modeling of Transient Thermography Inspection of Composite Materials

Several finite element models of defects such as debond and void have been developed for composite panels subjected to transient thermography inspection. Since the exact nature of the heat generated from the flash lamps is unknown, direct comparison between FEA and experimental results is not possible. However, some similarity of the results has been observed. The shape of the time curve that simulates the heat flux from the flash lamps has minimal effect on the temperature profiles. Double the number of flash lamps could increase the contrast of thermal image and define the shape of defect better.

Chu, Tsuchin Philip↗

NASA NTRS1998

Study Methods to Characterize and Implement Thermography Nondestructive Evaluation (NDE)

The limits and conditions under which an infrared thermographic nondestructive evaluation can be utilized to assess the quality of aerospace hardware is demonstrated in this research effort. The primary focus of this work is on applying thermography to the inspection of advanced composite structures such as would be found in the International Space Station Instrumentation Racks, Space Shuttle Cargo Bay Doors, Bantam RP-1 tank or RSRM Nose Cone. Here, the detection of delamination, disbond, inclusion and porosity type defects are of primary interest. In addition to composites, an extensive research effort has been initiated to determine how well a thermographic evaluation can detect leaks and disbonds in pressurized metallic systems "i.e. the Space Shuttle Main Engine Nozzles". In either case, research into developing practical inspection procedures was conducted and thermographic inspections were performed on a myriad of test samples, subscale demonstration articles and "simulated" flight hardware. All test samples were fabricated as close to their respective structural counterparts as possible except with intentional defects for NDE qualification. As an added benefit of this effort to create simulated defects, methods were devised for defect fabrication that may be useful in future NDE qualification ventures.

Walker, James L.↗

NASA NTRS2000

Visualization of In-Flight Flow Phenomena Using Infrared Thermography

Infrared thermography was used to obtain data on the state of the boundary layer of a natural laminar flow airfoil in supersonic flight. In addition to the laminar-to-turbulent transition boundary, the infrared camera was able to detect shock waves and present a time dependent view of the flow field. A time dependent heat transfer code was developed to predict temperature distributions on the test subject and any necessary surface treatment. A commercially available infrared camera was adapted for airborne use in this application. Readily available infrared technology has the capability to provide detailed visualization of various flow phenomena in subsonic to hypersonic flight regimes.

Banks, D. W.↗

NASA NTRS2001

Porosity Measurement in Laminated Composites by Thermography and FEA

This paper presents the correlation between the through-thickness thermal diffusivity and the porosity of composites. Finite element analysis (FEA) was used to determine the transient thermal response of composites that were subjected to laser heating. A series of finite element models were built and thermal responses for isotropic and orthographic materials with various thermal diffusivities subjected to different heating conditions were investigated. Experiments were conducted to verify the models and to estimate the unknown parameters such as the amount of heat flux. The analysis and experimental results show good correlation between thermal diffusivity and porosity in the composite materials. They also show that both laser and flash heating can be used effectively to obtain thermal diffusivity. The current infrared thermography system is developed for use with flash heating. The laser heating models and the FEA results can provide useful tools to develop practical thermal diffusivity measurement scheme using laser heat.

Chu, Tsuchin Philip↗

NASA NTRS2001

Advances in the Use of Thermography to Inspect Composite Tanks for Liquid Fuel Propulsion Systems

This viewgraph presentation gives an overview of advances in the use of thermography to inspect composite tanks for liquid fuel propulsion systems. Details are given on the thermographic inspection system, thermographic analysis method (includes scan and defect map, method of inspection, and inclusions, ply wrinkle, and delamination defects), graphite composite cryogenic feedline (including method, image map, and deep/shallow inclusions and resin rich area defects), and material degradation nondestructive evaluation.

Lansing, Matthew D.↗

NASA NTRS1999

Pulse Phase Thermography for Defect Detection and Visualization

Pulse Phase Thermography (PPT) has been reported as a novel powerful technique of the thermal NDE. It employs application of the Discrete Fourier Transform (DFT) to thermal images obtained following flash heating of the front surface of a specimen. The computed phasegrams are excellent for defect visualization in a wide range of materials. This is in part due to their low sensitivity to uneven heating. This work is an attempt to analyze advantages and limitations of PPT. Results of application of the DFT to simulated temperature decays are presented. The temperature evolution on a surface has been simulated based on an analytical solution of the one-dimensional heat diffusion problem. A more sophisticated study has been done for different sizes of defects using numerical solution of the three-dimensional mathematical model. Capabilities of PPT for in-depth scanning and for monitoring of the material loss are discussed. The recommendations for the practical application of the PPT are presented. Experimental results obtained following these recommendations are reported.

Marinetti, Sergio↗

NASA NTRS1998

Reduction and Analysis of Phosphor Thermography Data With the IHEAT Software Package

Detailed aeroheating information is critical to the successful design of a thermal protection system (TPS) for an aerospace vehicle. This report describes NASA Langley Research Center's (LaRC) two-color relative-intensity phosphor thermography method and the IHEAT software package which is used for the efficient data reduction and analysis of the phosphor image data. Development of theory is provided for a new weighted two-color relative-intensity fluorescence theory for quantitatively determining surface temperatures on hypersonic wind tunnel models; an improved application of the one-dimensional conduction theory for use in determining global heating mappings; and extrapolation of wind tunnel data to flight surface temperatures. The phosphor methodology at LaRC is presented including descriptions of phosphor model fabrication, test facilities and phosphor video acquisition systems. A discussion of the calibration procedures, data reduction and data analysis is given. Estimates of the total uncertainties (with a 95% confidence level) associated with the phosphor technique are shown to be approximately 8 to 10 percent in the Langley's 31-Inch Mach 10 Tunnel and 7 to 10 percent in the 20-Inch Mach 6 Tunnel. A comparison with thin-film measurements using two-inch radius hemispheres shows the phosphor data to be within 7 percent of thin-film measurements and to agree even better with predictions via a LATCH computational fluid dynamics solution (CFD). Good agreement between phosphor data and LAURA CFD computations on the forebody of a vertical takeoff/vertical lander configuration at four angles of attack is also shown. In addition, a comparison is given between Mach 6 phosphor data and laminar and turbulent solutions generated using the LAURA, GASP and LATCH CFD codes. Finally, the extrapolation method developed in this report is applied to the X-34 configuration with good agreement between the phosphor extrapolation and LAURA flight surface temperature predictions. The phosphor process outlined in the paper is believed to provide the aerothermodynamic community with a valuable capability for rapidly obtaining (4 to 5 weeks) detailed heating information needed in TPS design.

Merski, N. Ronald↗