Virtual reality robotic operation simulations using MEMICA Haptic System
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NDE NDT composite materials defects inspection↗
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Material Property Estimation in Thin Battery Components Using Guided Wave Measurement, Experimental Dispersion Curve Extraction and Finite Element Modeling
At NASA, we are investigating nondestructive evaluation (NDE) and structural health monitoring (SHM) techniques to detect precursors of thermal runaway failure in lithium metal based lithium ion batteries (LIB). The approach is centered on computational simulation models to guide inspection and aid in interpretation of results. Since lithium metal LIBs have combinations of solid and fluid-filled porous materials, obtaining accurate material properties is both challenging and critical for successful simulation of battery inspection. To this end, we investigated a multi-verification approach for material characterization of thin battery components. First, a laser Doppler vibrometer (LDV) was used to measure guided wave fields in thin (microns-thick) battery components subject to broadband excitation. The time-space wavefield data was converted to frequency-wave number data to extract guided wave dispersion curves. A data visualization and post processing graphics user interface (GUI) was developed at NASA to aid the data exploration and analysis. Due to the thinness of the samples, low frequency-thickness-product plate wave approximations allowed for the calculation of closed-form solutions for material elastic property estimation. These approximations were then verified by calculating the Lamb wave solutions using the previously obtained material properties. Finally, the estimated elastic material properties were implemented in a COMSOL simulation model, and dispersion curves were extracted from simulation results. The dispersion curves and derived material properties were then compared to the analysis results from the experimental data. These comparisons informed on the accuracy of the measured material properties and helped demonstrate the accuracy of the finite element analysis (FEA) computational models. This assessment will prove vital when we start simulating more complex multi-layer components and poroelastic media. This paper gives a brief background of the problem space, outlines the workflow for data analysis and verification, shows results from the workflow, and gives an overview of future plans for simulation of lithium metal LIB inspection.
Peter Juarez↗
Mechanical Properties and Real-Time Damage Evaluations of Environmental Barrier Coated SiC/SiC CMCs Subjected to Tensile Loading Under Thermal Gradients
SiC/SiC ceramic matrix composites (CMCs) require new state-of-the art environmental barrier coatings (EBCs) to withstand increased temperature requirements and high velocity combustion corrosive combustion gasses. The present work compares the response of coated and uncoated SiC/SiC CMC substrates subjected to simulated engine environments followed by high temperature mechanical testing to asses retained properties and damage mechanisms. Our focus is to explore the capabilities of electrical resistance (ER) measurements as an NDE technique for testing of retained properties under combined high heat-flux and mechanical loading conditions. Furthermore, Acoustic Emission (AE) measurements and Digital Image Correlation (DIC) were performed to determine material damage onset and accumulation.
Ceramic matrix composites↗
Models in the Design and Validation of Eddy Current Inspection for Cracking in the Shuttle Reaction Control System Thruster
A case study is presented for using models in eddy current NDE design for crack detection in Shuttle Reaction Control System thruster components. Numerical methods were used to address the complex geometry of the part and perform parametric studies of potential transducer designs. Simulations were found to show agreement with experimental results. Accurate representation of the coherent noise associated with the measurement and part geometry was found to be critical to properly evaluate the best probe designs.
Aldrin, John C.↗
NASA Tech Briefs, November 2012
The topics include: Visual System for Browsing, Analysis, and Retrieval of Data (ViSBARD); Time-Domain Terahertz Computed Axial Tomography NDE System; Adaptive Sampling of Time Series During Remote Exploration; A Tracking Sun Photometer Without Moving Parts; Surface Temperature Data Analysis; Modular, Autonomous Command and Data Handling Software with Built-In Simulation and Test; In-Situ Wire Damage Detection System; Amplifier Module for 260-GHz Band Using Quartz Waveguide Transitions; Wideband Agile Digital Microwave Radiometer; Buckyball Nucleation of HiPco Tubes; FACT, Mega-ROSA, SOLAROSA; An Integrated, Layered-Spinel Composite Cathode for Energy Storage Applications; Engineered Multifunctional Surfaces for Fluid Handling; Polyolefin-Based Aerogels; Adjusting Permittivity by Blending Varying Ratios of SWNTs; Gravity-Assist Mechanical Simulator for Outreach; Concept for Hydrogen-Impregnated Nanofiber/Photovoltaic Cargo Stowage System; DROP: Durable Reconnaissance and Observation Platform; Developing Physiologic Models for Emergency Medical Procedures Under Microgravity; Spectroscopic Chemical Analysis Methods and Apparatus; Low Average Sidelobe Slot Array Antennas for Radiometer Applications; Motion-Corrected 3D Sonic Anemometer for Tethersondes and Other Moving Platforms; Water Treatment Systems for Long Spaceflights; Microchip Non-Aqueous Capillary Electrophoresis (MicronNACE) Method to Analyze Long-Chain Primary Amines; Low-Cost Phased Array Antenna for Sounding Rockets, Missiles, and Expendable Launch Vehicles; Mars Science Laboratory Engineering Cameras; Seismic Imager Space Telescope; Estimating Sea Surface Salinity and Wind Using Combined Passive and Active L-Band Microwave Observations; A Posteriori Study of a DNS Database Describing Super critical Binary-Species Mixing; Scalable SCPPM Decoder; QuakeSim 2.0; HURON (HUman and Robotic Optimization Network) Multi-Agent Temporal Activity Planner/Scheduler; MPST Software: MoonKommand
Source record↗
A Probabilistic Model for Simulating Magnetoacoustic Emission Responses in Ferromagnets
Magnetoacoustic emission (MAE) is a phenomenon where acoustic noise is generated due to the motion of non-180 magnetic domain walls in a ferromagnet with non-zero magnetostrictive constants. MAE has been studied extensively for many years and has even been applied as an NDE tool for characterizing the heat treatment of high-yield low carbon steels. A complete theory which fully accounts for the magnetoacoustic response, however, has not yet emerged. The motion of the domain walls appears to be a totally random process, however, it does exhibit features of regularity which have been identified by studying phenomena such as 1/f flicker noise and self-organized criticality (SOC). In this paper, a probabilistic model incorporating the effects of SOC has been developed to help explain the MAE response. The model uses many simplifying assumptions yet yields good qualitative agreement with observed experimental results and also provides some insight into the possible underlying mechanisms responsible for MAE. We begin by providing a brief overview of magnetoacoustic emission and the experimental set-up used to obtain the MAE signal. We then describe a pseudo-probabilistic model used to predict the MAE response and give an example of the predicted result. Finally, the model is modified to account for SOC and the new predictions are shown and compared with experiment.
Namkung, M.↗
Optimal application of Morrison's iterative noise removal for deconvolution
Morrison's iterative method of noise removal can be applied for both noise removal alone and noise removal prior to deconvolution. This method is applied to noise of various noise levels added to determine the optimum use of the method. The phase shift method of migration and modeling is evaluated and the results are compared to Stolt's approach. A method is introduced by which the optimum iterative number for deconvolution can be found. Statistical computer simulation is used to describe the optimum use of two convergent iterative techniques for seismic data. The Always-Convergent deconvolution technique was applied to data recorded during the quantitative analysis of materials through NonDestructive Evaluation (NDE) in which ultrasonic signals were used to detect flaws in substances such as composites.
Ioup, George E.↗
Fracture Mechanics Analysis of LH2 Feed Line Flow Liners
Inspections of the Space Shuttle Main Engine revealed fatigue cracks growing from slots in the flow liner of the liquid hydrogen (LH2) feed lines. During flight, the flow liners experience complex loading induced by flow of LH2 and the resonance characteristics of the structure. The flow liners are made of Inconel 718 and had previously not been considered a fracture critical component. However, fatigue failure of a flow liner could have catastrophic effect on the Shuttle engines. A fracture mechanics study was performed to determine if a damage tolerance approach to life management was possible and to determine the sensitivity to the load spectra, material properties, and crack size. The load spectra were derived separately from ground tests and material properties were obtained from coupon tests. The stress-intensity factors for the fatigue cracks were determined from a shell-dynamics approach that simulated the dominant resonant frequencies. Life predictions were obtained using the NASGRO life prediction code. The results indicated that adequate life could not be demonstrated for initial crack lengths of the size that could be detected by traditional NDE techniques.
James, Mark A.↗
Transfer Function Models and Sensitivity Analysis
In many situations, real or induced flaws such as tight cracks with known morphology cannot be manufactured in part configuration specimens or in real parts. Typically, fatigue cracks are manufactured in simple geometry specimens such as flat plates, dog-bone shaped flat or round specimens. If a nondestructive evaluation (NDE) technique is required to provide a reliably detectable target flaw size denoted as α_(90/95) for induced flaws in real part, then the direct method for qualifying the NDE procedure is to use the appropriate induced flaw specimens and perform probability of detection analysis using these flaws. This can be described as direct POD demonstration testing, which may follow guidelines of MIL-HDBK-1823. This paper considers a case, where induced flaws are not available in part configuration specimens. Therefore, a direct POD demonstration study cannot be undertaken. In such situation, general practice for NDE procedure qualification is to use artificial flaws in simple geometry and part configuration specimens, and induced flaws in the chosen simple geometry specimens. Signal response data is taken on all sets of artificial and induced flaws. NDE procedure testing on induced flaw in simple geometry specimen is called NDE demonstration testing here. A transfer function NDE procedure qualification method for forward case calculates predicted induced flaw size for demonstration using a chosen target flaw size. Another transfer function method for inverse case, calculates the target flaw size using a given demonstration flaw size. The transfer function analysis assumes relationship of artificial flaw signal responses in real parts and simple geometry specimens; and induced flaw responses in simple geometry specimens to induced flaws in real parts. The signal response transfer relationships model should be defined before transfer function models can be devised. Assuming that the signal response transfer relationships model is valid, forward and inverse case transfer function methods have been devised. Because of lack of signal response data from induced flaws in real part, 90/95% POD/confidence (P/C) cannot be demonstrated directly. However, the transfer function method may be assessed using simulation to evaluate whether the resulting target flaw size or demonstration flaw size provides adequate confidence to the assumed signal response transfer relationships model. Therefore, the transfer function approach is a risk assessment approach. Both the signal response transfer relationships model and the transfer function model are important in managing risk in results provided by the transfer function NDE technique qualification or assessment. The signal response transfer relationships model needs to be validated with empirical data and then transfer function model needs to be validated for desired P/C on case-by-case basis.
Nondestructive evaluation↗
Improved Sizing of Impact Damage in Composites Based on Thermographic Response
Impact damage in thin carbon fiber reinforced polymer composites often results in a relatively small region of damage at the front surface, with increasing damage near the back surface. Conventional methods for reducing the pulsed thermographic responses of the composite tend to underestimate the size of the back surface damage, since the smaller near surface damage gives the largest thermographic indication. A method is presented for reducing the thermographic data to produce an estimated size for the impact damage that is much closer to the size of the damage estimated from other NDE techniques such as microfocus x-ray computed tomography and pulse echo ultrasonics. Examples of the application of the technique to experimental data acquired on specimens with impact damage are presented. The method is also applied to the results of thermographic simulations to investigate the limitations of the technique.
Winfree, William P.↗
Quadrupole Simulations of Thermographic Responses of Composites
Thermography has been shown to be a viable technique for inspection of composites. The quadrupole method has been shown as a viable technique for rapidedly simulating the thermal repsonse of layered systems. Often, the effort has focused on a one-dimentional models, in particular for improved analysis of thermal data. For composites, the in-plane heat diffusion often significantly impacts the thermal response of defects of interest, therefore three-dimensional simulations are desirable. This paper discusses the extension of the quadrupole methodology to perform simulations of thermographic responses in three-dimensional configuration. This enables the more realistic simulations of the thermal response of delaminiations in composites. The simulations are compared to finite element simulations of the same inspection configurations. The simulations are also compared to the thermographic measurements on composites where shape and depth of the delaminations are known obtained from other sources.
Thermography↗
Low Temperature SQUID for NDE Applications
We have developed a low temperature SuperConducting Quantum Interference Device - SQUID measurement system for detection of defects deep under the surface of aluminum structures using eddy current techniques. The system uses a two dimensional planar inducer with two different excitation frequencies to induce a current in the sample. We have developed a data analysis software program that enabled us to distinguish between round defects (holes), straight defects (slots) and slots close to holes simulating cracks starting from rivets in aluminum structures. We were able to detect defects that are 8mm below the surface. We have also measured the change in phase of the detected signal as a function of depth of the defect. This relationship can be used to determine the depth of hidden flaws. Using this analysis software with the high temperature SQUID system at NASA Langley we were able to detect slots close to holes in layered aluminum sample.
Wincheski, Buzz↗
Results of On-Orbit Testing of an Extra-Vehicular Infrared Camera Inspection System
This paper will discuss an infrared camera inspection system that has been developed to allow astronauts to demonstrate the ability to inspect reinforced carbon-carbon (RCC) components on the space shuttle as part of extra-vehicular activities (EVA) while in orbit. Presented will be the performance of the EVA camera system coupled with solar heating for inspection of damaged RCC specimens and NDE standards. The data presented was acquired during space shuttle flights STS-121 and STS-115 as well during a staged EVA from the ISS. The EVA camera system was able to detect flatbottom holes as small as 2.54cm in diameter with 25% material loss. Results obtained are shown to be comparable to ground-based thermal inspections performed in the laboratory using the same camera and simulated solar heating. Data on both the time history of the specimen temperature and the ability of the inspection system to image defects due to impact will likewise be presented.
Howell, Patricia A.↗
Lamb wave defect detection and evaluation using a fully non-contact laser system
Traditional Lamb wave structural health monitoring (SHM)/nondestructive evaluation (NDE) system employs contact type transducers such as PZT, ultrasonic transducers, and optical fibers. In application, transducer attachment and maintenance can be time and labor consuming. In addition, the use of couplant and adhesives can introduce additional materials on structures, and the interface coupling is often not well understood. To overcome these limitations, we proposed a fully non-contact NDE system by employing pulsed laser (PL) for Lamb wave actuation and scanning laser Doppler vibrometer (SLDV) for Lamb wave sensing. The proposed system is implemented on aluminum plates. The PL Lamb wave excitation is calibrated, and the optimal parameters are obtained. Lamb wave modes are then characterized through 1D wavefield analysis. With the calibrated and characterized system, defect detection and evaluation are achieved on aluminum plates with simulated defects (surfaced-bonded quartz rod, and machine milled crack) through 1D and 2D inspection in both time-space and frequency-wavenumber domains.
Ma, Zhaoyun↗
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↗
The Inspectability Metric: A Formalized System Of Measurement Enabling The Design For Inspection Framework
Nondestructive evaluation (NDE) engineers are often confronted with structural design choices that present challenges to meeting inspection requirements. These challenges, at best, increase the resources needed to design an inspection solution and, at worst, require resource intensive redesign of the structure. If the inspectability of the structure can be determined early in the design cycle, these challenging inspection scenarios can be avoided. The emergence of additive manufacturing has further compounded this problem by enabling the creation of highly optimized structures with no regard to inspection constraints. Design for inspection (DFI) offers a framework to integrate nondestructive evaluation (NDE) into the design process to alleviate the mechanisms that produce uninspectable designs. DFI is the concept of including inspectability in a multi-objective optimization framework so that it can be considered in parallel to other metrics such as mass and manufacturability. This allows rapid evaluation of the trade-off between design metrics to find solutions that meet the inspection needs of a particular material system, structural concept, or vehicle program. To enable DFI, there must be a system by which the inspectability of a structure can be measured. This system must be agile to produce results quickly, it must be versatile to work with the type of incomplete information one would encounter early in the design process (such as lack of inspection requirements), and it must be delivered in a form that is easily understood by designers. To meet this need, this presentation introduces the novel inspectability metric as a system to measure inspectability. The inspectability metric is a standardized, automation friendly procedure that uses simulations to determine inspectability. Along with guidelines to properly process designs and integrate with existing workflows, the inspectability metric provides a suite of simulation tests to interrogate the ability to find defects and the sensitivity to variability. The testing rubric is designed to maximize the coverage of the parameter space while minimizing the number of simulations needed. The inspectability metric has been in development in collaboration with industry partners to ensure compatibility with modern simulation tools and aerospace design workflows. In this study, we will demonstrate how the inspectability metric is able to determine the inspectability of multiple types of structures, including aerospace composites and additively manufactured parts. We will then show how the inspectability score can be plugged into existing design optimization tasks, such as structural sizing algorithms or design for manufacturing (DFM) frameworks.
Design for inspection↗
Lack of Penetration in Friction Stir Welds: Effects on Mechanical Properties and NDE Feasibility
This presentation reviews the issue of lack of penetration (LOP) in Friction Stir Welding and the feasibility of using non-destructive tests to detect . Friction Stir Welding takes place in the solid phase below the melting point of the materials to be joined. It thus gives the ability to join materials which are difficult to fusion weld, for example 2000 and 7000 aluminium alloys. This process though can result in a lack of penetration, due to an incomplete penetration of the DXZ. This is frequently referred to as a "kissing bond", which requires micro examination to detect. The presentation then discusses the surface crack tension tests. It then reviews the simulated service test and results. It then discusses the feasibility of using non-destructive examination to detect LOP, the forms of test which can be used, and the results the tests.
Kinchen, David G.↗