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NASA NTRS1984

Ultrasonic nondestructive evaluation, microstructure, and mechanical property interrelations

Ultrasonic techniques for mechanical property characterizations are reviewed and conceptual models are advanced for explaining and interpreting the empirically based results. At present, the technology is generally empirically based and is emerging from the research laboratory. Advancement of the technology will require establishment of theoretical foundations for the experimentally observed interrelations among ultrasonic measurements, mechanical properties, and microstructure. Conceptual models are applied to ultrasonic assessment of fracture toughness to illustrate an approach for predicting correlations found among ultrasonic measurements, microstructure, and mechanical properties.

Vary, A.↗

NASA NTRS1987

Ultrasonic nondestructive evaluation, microstructure, and fracture toughness interrelations

Vary, Alex↗

DOE OSTI2021

Characterization of mechanical deformation in aluminum by optical second harmonic generation

Second harmonic generation (SHG), a laser-based surface technique, was used to characterize near-surface defect evolution associated with mechanical deformation in 2024-T3 aluminum due to tensile loads. Electron backscatter diffraction (EBSD) measurements were also performed to determine the geometrically necessary dislocation density before and after tensile deformation. Comparison of the EBSD and SHG results found that dislocation density and SHG signal are inversely proportional; tensile deformation in the plastic regime led to an increase in dislocation density and a decrease in SHG response. A similar trend was seen in the SHG results on as-received (unpolished) Al samples; SHG response decreases with extent of plastic deformation. Furthermore, this study suggests that SHG has potential as a nondestructive evaluation technique.

36 MATERIALS SCIENCE↗

NASA NTRS1987

Statistical Tests of Reliability of NDE

Capabilities of advanced material-testing techniques analyzed. Collection of four reports illustrates statistical method for characterizing flaw-detecting capabilities of sophisticated nondestructive evaluation (NDE). Method used to determine reliability of several state-of-the-art NDE techniques for detecting failure-causing flaws in advanced ceramic materials considered for use in automobiles, airplanes, and space vehicles.

Baaklini, George Y.↗

NASA NTRS2012

Thermography Inspection for Early Detection of Composite Damage in Structures During Fatigue Loading

Advanced composite structures are commonly tested under controlled loading. Understanding the initiation and progression of composite damage under load is critical for validating design concepts and structural analysis tools. Thermal nondestructive evaluation (NDE) is used to detect and characterize damage in composite structures during fatigue loading. A difference image processing algorithm is demonstrated to enhance damage detection and characterization by removing thermal variations not associated with defects. In addition, a one-dimensional multilayered thermal model is used to characterize damage. Lastly, the thermography results are compared to other inspections such as non-immersion ultrasonic inspections and computed tomography X-ray.

Zalameda, Joseph N.↗

NASA NTRS2020

In-Flight Detection of Vibration Anomalies in Unmanned Aerial Vehicles

Owing to the frequency of occurrence and high risk associated with bearings, identification and characterization of bearing faults in motors via nondestructive evaluation (NDE) methods have been studied extensively, amongst which vibration analysis has been found to be a promising technique for early diagnosis of anomalies. However, a majority of the existing techniques rely on vibration sensors attached onto or in close proximity to the motor in order to collect signals with a relatively high SNR. Due to weight and space restrictions, these techniques cannot be used in unmanned aerial vehicles (UAVs), especially during flight operations since accelerometers cannot be attached onto motors in small UAVs. Small UAVs are often subjected to vibrational disturbances caused by multiple factors such as weather turbulence, propeller imbalance or bearing faults. Such anomalies may not only pose risks to UAV's internal circuitry, components or payload, they may also generate undesirable noise level particularly for UAVs expected to fly in low-altitudes or urban canyon. This paper presents a detailed discussion of challenges in in-flight detection of bearing failure in UAVs using existing approaches and offers potential solutions to detect overall vibration anomalies in small UAV operations based on IMU data.

Portia Banerjee↗

DOE OSTI2026

Nondestructive ultrasonic characterization of a triple-weld-bead wire arc additively manufactured ER70S-6 S-curved wall

Understanding build-scale microstructural variation in wire arc additive manufacturing (WAAM) of low-carbon steels is essential for ensuring consistent structure–property relationships throughout large components. Conventional destructive characterization techniques, such as scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD), are time-intensive and limited to localized regions, making comprehensive evaluation of large WAAM structures challenging. In this study, a nondestructive ultrasonic approach was employed to characterize a 252 mm tall ER70S-6 S-curved WAAM wall produced using a triple-bead deposition strategy. Optical and SEM analysis revealed a repeating dual-region microstructure consisting of uniform polygonal ferrite at melt pool centers and heterogeneous ferrite with coarse and fine grains near melt pool boundaries, attributed to cyclic thermal conditions. Longitudinal ultrasonic backscatter imaging was used to evaluate the continuity of this periodicity along the full build height. The ultrasonic response exhibited a consistent repeating pattern that correlated with the observed layer-wise microstructural variation. X-ray computed tomography confirmed the absence of detectable porosity, indicating that ultrasonic contrast is primarily governed by grain morphology. Overall, the results indicate that longitudinal backscatter ultrasound is a promising nondestructive characterization technique for validating microstructural variations along the s-curved WAAM wall, with significant potential for microstructure optimization and process control.

36 MATERIALS SCIENCE↗

NASA NTRS2004

Ultrasonic Guided-Wave Scan System Used to Characterize Microstructure and Defects in Ceramic Composites

Ceramic matrix composites (CMCs) are being developed for advanced aerospace propulsion applications to save weight, improve reuse capability, and increase performance. However, mechanical and environmental loads applied to CMCs can cause discrete flaws and distributed microdamage, significantly reducing desirable physical properties. Such microdamage includes fiber/matrix debonding (interface failure), matrix microcracking, fiber fracture and buckling, oxidation, and second phase formation. A recent study (ref. 1) of the durability of a C/SiC CMC discussed the requirement for improved nondestructive evaluation (NDE) methods for monitoring degradation in these materials. Distributed microdamage in CMCs has proven difficult to characterize nondestructively because of the complex microstructure and macrostructure of these materials. This year, an ultrasonic guided-wave scan system developed at the NASA Glenn Research Center was used to characterize various microstructural and flaw conditions in SiC/SiC (silicon carbide fiber in silicon carbide matrix) and C/SiC (carbon fiber in silicon carbide matrix) CMC samples.

Roth, Don J.↗

DOE OSTI2023

Beta-Stabilized Ti-5Al-5Mo-5V-3Cr Primary and Secondary Phase Characterization using Ultrasonic Attenuation

Ti-5Al-5Mo-5V-3Cr (Ti-5553) is a beta-stabilized titanium alloy being evaluated for its use in additive manufacturing. The development of effective nondestructive characterization tools will be critical for successful insertion of Ti-5553 into applications. The microstructure of Ti-5553 can be modified significantly, through heat treatments alone, to produce single β-phase microstructure or dual α-β microstructure with variations on the types and quantities of the α phase in a β matrix. In this work, a set of heat treatments was chosen to obtain a range of microstructures, followed by an investigation of the ultrasonic response to gauge the degree to which these variations could be detected. Ultrasonic attenuation was selected because of its ability to detect differences in grain size and, potentially, the existence and limited details of secondary phases . Initial results show a very distinctive difference in attenuation between the single phase β and the α+β microstructures, and smaller, but still significant, differences among the α+β microstructures indicating that this approach merits further development.

ultrasonic attenuation, Ti-5Al-5Mo-5V-3Cr, heat tr↗

NASA NTRS2007

Application of Raman Spectroscopy for Nondestructive Evaluation of Composite Materials

This paper will present an overview of efforts to investigate the application of Raman spectroscopy for the characterization of Kevlar materials. Raman spectroscopy is a laser technique that is sensitive to molecular interactions in materials such as Kevlar, graphite and carbon used in composite materials. The overall goal of this research reported here is to evaluate Raman spectroscopy as a potential nondestructive evaluation (NDE) tool for the detection of stress rupture in Kevlar composite over-wrapped pressure vessels (COPVs). Characterization of the Raman spectra of Kevlar yarn and strands will be presented and compared with analytical models provided in the literature. Results of testing to investigate the effects of creep and high-temperature aging on the Raman spectra will be presented.

Washer, Glenn A.↗

NASA NTRS2016

An Assessment of Nondestructive Evaluation Capability for Complex Additive Manufacturing Aerospace Components

The primary focus of this work is to investigate some of the fundamental relationships between processing, mechanical testing, materials characterization, and NDE for additively manufactured (AM) components using the powder bed fusion direct melt laser sintered process. The goal is to understand the criticality of defects unique to the AM process and then how conventional nondestructive evaluation methods as well as some of the more non-traditional methods such as computed tomography, are effected by the AM material. Specific defects including cracking, porosity and partially/unfused powder will be addressed. Besides line-of-site NDE, as appropriate these inspection capabilities will be put into the context of complex AM geometries where hidden features obscure, or inhibit traditional NDE methods.

Walker, James↗

DOE OSTI2026

Ultrasonic Resonance Techniques for Materials Research

Mechanical resonances are directly related to the physical behavior of a system at the bulk and microscopic levels. In materials science, resonant ultrasound spectroscopy (RUS) has long been a preferred nondestructive method to study mechanical resonances of solids and precisely measure quantitative material properties, namely elasticity. In recent years, advances in computational power and hardware have enabled RUS to be relevant for an increasing range of applications, such as advanced manufacturing. An extension of this technique, nonlinear RUS (NRUS), has been demonstrated to provide unmatched sensitivity to early-stage damage. NRUS was originally developed to probe geologic materials but has become a vital tool in nondestructive evaluation and materials research, offering a powerful means of quantifying and characterizing microstructural nonlinearity in a broad range of materials. This review summarizes recent developments and growth opportunities in RUS and NRUS techniques, modeling, and applications across a wide range of material systems including metals, composites, geomaterials, and explosives.

36 MATERIALS SCIENCE↗

NASA NTRS1992

Nondestructive evaluation of ceramic and metal matrix composites for NASA's HITEMP and enabling propulsion materials programs

In a preliminary study, ultrasonic, x-ray opaque, and fluorescent dye penetrants techniques were used to evaluate and characterize ceramic and metal matrix composites. Techniques are highlighted for identifying porosity, fiber alignment, fiber uniformity, matrix cracks, fiber fractures, unbonds or disbonds between laminae, and fiber-to-matrix bond variations. The nondestructive evaluations (NDE) were performed during processing and after thermomechanical testing. Specific examples are given for Si3N4/SiC (SCS-6 fiber), FeCrAlY/Al2O3 fibers, Ti-15-3/SiC (SCS-6 fiber) materials, and Si3N4/SiC (SCS-6 fiber) actively cooled panel components. Results of this study indicate that the choice of the NDE tools to be used can be optimized to yield a faithful and accurate evaluation of advanced composites.

Generazio, Edward R.↗

NASA NTRS1980

Notched graphite polymimide composites at room and notched graphite polymide composites at room and elevated temperatures

The fracture behavior in graphite/polyimide (Gr/PI) Celion 6000/PMR-15 composites was characterized. Emphasis was placed on the correlation between the observed failure modes and the deformation characteristics of center-notched Gr/Pl laminates. Crack tip damage growth, fracture strength and notch sensitivity, and the associated characterization methods were also examined. Special attention was given to nondestructive evaluation of internal damage and damage growth, techniques such as acoustic emission, X-ray radiography, and ultrasonic C-scan. Microstructural studies using scanning electron microscopy, photomicrography, and the pulsed nuclear magnetic resonance technique were employed as well. All experimental procedures and techniques are described and a summary of representative results for Gr/Pl laminates is given.

Awerbuch, J.↗

DOE OSTI2023

Internal defect detection and characterization of samarium-cobalt sintered magnets by ultrasonic testing technique

Excessive quantities of samarium-cobalt (Sm-Co) magnet material are being scrapped needlessly due to a lack of understanding of inhomogeneity distribution and unacceptable internal defects. If there is a way to identify, locate, characterize and when needed separate the defective portions of magnet material, utilization can be increased and product quality improved. Further, the magnets’ magnetic and mechanical performance can be improved by reducing the occurrence of internal defects. This paper reports on a cost-effective and efficient nondestructive evaluation method based on an ultrasonic testing (UT) technique applied for detecting and characterizing internal defects in Sm-Co sintered magnets. Applying the UT technique will allow users to comprehensively analyze internal defects, such as inclusions, porosity, microcracks, and other structural irregularities, check for homogeneity and anomalous regions and give the locations of these internal anomalies and defects within the Sm-Co sintered magnets. The UT technique can also be applied to other rare-earth permanent magnets, such as sintered or die-upset neodymium-iron-boron (Nd-Fe-B) magnets. The UT technique can effectively guide quality control and acceptable product selection, in addition to optimizing the magnet alloy design and production processes. Therefore, it can facilitate the improvement of magnet manufacturing efficiency and machinability, reduce scrap, prolong service life, increase the use of what would be post-production waste, and enhance product reuse and recycling at end-of-life disposition.

36 MATERIALS SCIENCE↗

NASA NTRS1980

Concepts and techniques for ultrasonic evaluation of material mechanical properties

The ultrasonic nondestructive evaluation techniques discussed in the present paper indicate potentials for material characterization and property prediction. Stress wave interaction and material transfer function concepts are examined as a basis for explaining correlations between material mechanical behavior and ultrasonically measured quantities. It is observed that the effect and criticality of any discrete flaw, such as crack, inclusion, or any other stress raiser, is definable only in terms of its material microstructural environment. This underscores the importance of ultrasonic techniques capable of characterizing the stress wave energy transfer properties of a material.

Vary, A.↗

NASA NTRS2001

Labview Interface Concepts Used in NASA Scientific Investigations and Virtual Instruments

This article provides an overview of several software control applications developed for NASA using LabVIEW. The applications covered here include (1) an Ultrasonic Measurement System for nondestructive evaluation of advanced structural materials, an Xray Spectral Mapping System for characterizing the quality and uniformity of developing photon detector materials, (2) a Life Testing System for these same materials, (3) and the instrument panel for an aircraft mounted Cloud Absorption Radiometer that measures the light scattered by clouds in multiple spectral bands. Many of the software interface concepts employed are explained. Panel layout and block diagram (code) strategies for each application are described. In particular, some of the more unique features of the applications' interfaces and source code are highlighted. This article assumes that the reader has a beginner-to-intermediate understanding of LabVIEW methods.

Roth, Don J.↗

NASA NTRS1997

Application of the Pseudo Wigner-Ville Distribution to the Measurement of the Dispersion of Lamb Modes in Graphite/Epoxy Plates

Acoustic waves propagate in thin plates as guided or Lamb modes. The velocities of these modes are dispersive in that they depend not only on the material elastic properties and density, but also on the frequency. Accurate characterization of Lamb wave dispersion is important in many acoustic based nondestructive evaluation techniques. It is necessary for ultrasonic measurements in thin plates to determine elastic properties and for flaw detection and localization. In acoustic emission (AE) testing, if not taken into account, highly dispersive Lamb mode propagation can lead to large errors in source location. In this study, the pseudo Wigner-Ville distribution (PWVD) was used for measurement of group velocity dispersion of Lamb waves in a unidirectional graphite/epoxy (AS4/3502) laminate. The PWVD is one of a number of transforms which provide a time-frequency representation of a digitized time series. Broad band acoustic waves were generated by a pencil lead fracture (Hsu-Neilsen source) and were detected with broad band ultrasonic transducers. The arrival times for the lowest order symmetric (S(sub 0)) and antisymmetric (A(sub 0)) Lamb modes were determined from measurements of the time at which the respective peak amplitudes occurred in the PWVD. Measurements were made at several source-to-detector distances and a least squares fit used to calculate the velocity. Results are presented for propagation along, and perpendicular to, the fiber direction. Theoretical dispersion curves were also calculated and a comparison between theory and experiment demonstrates good agreement.

Prosser, W. H.↗