Development of ultrasonic testing techniques for Saturn honeycomb heat shields.
Ultrasonic techniques for nondestructive testing for Saturn honeycomb heat shields
HEAT SHIELD↗
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In-Process Monitoring and Structural Health Monitoring of Large-Scale Additive Manufacturing Using Acoustic Emission Technique
ORNL collaborated with MISTRAS Group, Inc. to investigate acoustic emission (AE) as a structural health monitoring (SHM) method for large-scale additive manufacturing (AM). Large-scale AM is being adapted as method of producing large structures in a short lead time and cost-effective way. With the growing advancement in AM techniques and application, machine monitoring and part qualification is highly needed. There has been leading research focused on the manufacturing, feedstock material but minimum research on the SHM, defect detection, and nondestructive evaluation (NDE) for AM. Scanning large structure using conventional nondestructive testing (NDT) techniques, such as ultrasound or X-ray, and searching for potential defects can be very time consuming, challenging and cost prohibitive. AE is a passive technique that can be used to monitor and locate defect progression in large structure by distributing group of sensors around the part. This project utilized AE technique and system manufactured/designed by MISTRAS Group to monitor large-scale AM equipment (i.e. Big Area Additive Manufacturing (BAAM) system located at the Oak Ridge National Laboratory – Manufacturing Demonstration Facility (ORNL-MDF) and the printed parts it produces. The AE system provided valuable insight on defect development/progression during and post-printing process.
36 MATERIALS SCIENCE↗
Nondestructive Ultrasonic Inspection of Composite Materials: A Comparative Advantage of Phased Array Ultrasonic
Carbon- and glass fiber-reinforced polymer (CFRP and GFRP) composite materials have been used in many industries such as aerospace and automobile because of their outstanding strength-to-weight ratio and corrosion resistance. The quality of these materials is important for safe operation. Nondestructive testing (NDT) techniques are an effective way to inspect these composites. While ultrasonic NDT has previously been used for inspection of composites, conventional ultrasonic NDT, using single element transducers, has limitations such as high attenuation and low signal-to-noise ratio (SNR). Using phased array ultrasonic testing (PAUT) techniques, signals can be generated at desired distances and angles. These capabilities provide promising results for composites where the anisotropic structure makes signal evaluation challenging. Defect detection in composites based on bulk and guided waves are studied. The capability of the PAUT and its sensitivity to flaws were evaluated by comparing the signal characteristics to the conventional method. The results show that flaw sizes as small as 0.8 mm with penetration depth up to 25 mm can be detected using PAUT, and the result signals have better characteristics than the conventional ultrasonic technique. In addition, it has been shown that guided wave generated by PAUT also has outstanding capability of flaw detection in composite materials.
36 MATERIALS SCIENCE↗
Applying Acoustic Emission to Large Format Additive Manufacturing
Large format additive manufacturing (AM) is being adapted as a method of producing large structures in a short lead time and cost-effective way. With the growing advancement in AM techniques and application, machine monitoring and part qualification is highly needed. There has been leading research focused on the manufacturing development and feedstock material but minimum research on the structural health monitoring (SHM), defect detection, and nondestructive evaluation (NDE) for large format AM. Scanning large structure using conventional nondestructive testing (NDT) techniques, such as ultrasound or X-ray, and searching for potential defects can be very time consuming, challenging and cost prohibitive. Acoustic emission (AE) is a passive technique that can be used to monitor and locate defect progression in large structures by distributing group of sensors around the part. This research outlines the necessary procedure for implementing AE to AM as a reliability method. The topics this research will display are: (a) Wave propagation/velocity evaluation, (b) an AE attenuation characterization for the anisotropic printed structure and material, (c) background noise measurements of the extruder and gantry system, and (d) assist in optimal sensor selection and placement for monitoring large AM structures with demonstration. This work establishes the foundation for scaling up the SHM-AE system for the large additive platform.
Spencer, Ryan↗
Universal test fixture for monolithic mm-wave integrated circuits calibrated with an augmented TRD algorithm
The design and evaluation of a novel fixturing technique for characterizing millimeter wave solid state devices is presented. The technique utilizes a cosine-tapered ridge guide fixture and a one-tier de-embedding procedure to produce accurate and repeatable device level data. Advanced features of this technique include nondestructive testing, full waveguide bandwidth operation, universality of application, and rapid, yet repeatable, chip-level characterization. In addition, only one set of calibration standards is required regardless of the device geometry.
Romanofsky, Robert R.↗
Solid rocket motor nozzles
The steps in the nozzle design process are examined. The nozzle designer's role in defining design requirements and constraints is included along with discussions of each of the three basic phases of the nozzle design process itself: (1) aerodynamic design, in which the gas-contacting surfaces are configured to produce the required performance within the envelope limits; (2) thermal design, in which termal liners and thermal insulators are selected and configured to maintain the surfaces as closely as practical against effects of erosion and to limit the structure temperature to acceptable levels; and (3) structural design, in which materials are selected and configured to support the thermal components and to sustain the predicted loads. Analytical techniques that are used to establish thermal and structural design integrity and to predict nozzle performance are discussed along with methods for nozzle quality assurance. Emphasis is placed on nozzle design and materials for modern high-temperature aluminized propellants. Recurring nozzle design problems of graphite cracking and ejection, differential erosion at material interfaces, lack of sufficient proven nondestructive testing (NDT) techniques, the uncertainty of adhesive bonding, and inadequate definition of material properties, particularly at high temperatures are considered.
Ellis, R. A.↗
Sensor Fusion Techniques for Phased-Array Eddy Current and Phased-Array Ultrasound Data
Sensor (or Data) fusion is the process of integrating multiple data sources to produce more consistent, accurate and comprehensive information than is provided by a single data source. Sensor fusion may also be used to combine multiple signals from a single modality to improve the performance of a particular inspection technique. Industrial nondestructive testing may utilize multiple sensors to acquire inspection data depending upon the object under inspection and the anticipated types of defects that can be identified. Sensor fusion can be performed at various levels of signal abstraction with each having its strengths and weaknesses. A multimodal data fusion strategy first proposed by Heideklang and Shokouhi that combines spatially scattered detection locations to improve detection performance of surface-breaking and near-surface cracks in ferromagnetic metals is shown using a surface inspection example and is then extended for volumetric inspections. Utilizing data acquired from an Olympus Omniscan MX2 from both phased array eddy current and ultrasound probes on test phantoms, single and multilevel fusion techniques are employed to integrate signals from the two modalities. Preliminary results demonstrate how confidence in defect identification and interpretation benefit from sensor fusion techniques. Lastly, techniques for integrating data into radiographic and volumetric imagery from computed tomography are described and results are presented.
38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
Demonstrating resonant ultrasound spectroscopy as a viable technique to characterize thermally conditioned high explosive materials
We present results of resonant ultrasound spectroscopy (RUS) measurements applied to granular high explosive materials at different bulk pressing densities and degree of thermal conditioning. The material chosen in this study is a ubiquitously used explosive material known as pentaerythritol tetranitrate (PETN), which is used commercially in civil and defense applications both as a binderized plastic bonded explosive material and an unbinderized neat material. However, changes in granular PETN bulk elastic properties due to thermal conditioning, which could have implications for better understanding environmental aging-related effects, have not been well studied even though it is believed that elasticity may play an important role in explosive material initiation mechanisms. Furthermore, monitoring elastic property changes in granular explosive pressings has not yet been demonstrated using RUS, which is an appealing non-destructive characterization tool that requires only dry point contact with the explosive material. To this end, we report the first study using RUS to quantify the elastic properties of binderized and neat PETN pressings as well as to quantify changes in elastic properties as a function of both thermal conditioning and bulk pressing density. Elastic stiffness coefficients, sometimes more commonly referred to as elastic constants, calculated from the RUS measurements on the different PETN-based materials show a significant increase for the post-conditioned samples compared to the pre-conditioned samples. This trend of increasing elastic properties with thermal conditioning was consistent for different density pressings, different thermal exposure conditions, and even different neat PETN pressings of differing average crystal sizes and/or specific surface areas.
36 MATERIALS SCIENCE↗
Simulation of crack induced nonlinear elasticity using the combined finite-discrete element method
Numerical simulation of nonlinear elastic wave propagation in solids with cracks is indispensable for decoding the complicated mechanisms associated with the nonlinear ultrasonic techniques in NonDestructive Testing (NDT). Here, we introduce a two-dimensional implementation of the combined finitediscrete element method (FDEM), which merges the finite element method (FEM) and the discrete element method (DEM), to explicitly simulate the crack induced nonlinear elasticity in solids with both horizontal and inclined cracks. In the FDEM model, the solid is discretized into finite elements to capture the wave propagation in the bulk material, and the finite elements along the two sides of the crack also behave as discrete elements to track the normal and tangential interactions between crack surfaces. The simulation results show that for cracked models, nonlinear elasticity is generated only when the excitation amplitude is large enough to trigger the contact between crack surfaces, and the nonlinear behavior is very sensitive to the crack surface contact. The simulations reveal the influence of normal and tangential contact on the nonlinear elasticity generation. Moreover, the results demonstrate the capabilities of FDEM for decoding the causality of nonlinear elasticity in cracked solid and its potential to assist in Non-Destructive Testing (NDT).
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
Narrow band photoacoustic lamb wave generation for nondestructive testing using candle soot nanoparticle patches
The generation of ultrasonic surface waves with a photoacoustic-laser-source has become useful for the noncontact nondestructive testing and evaluation (NDT&E) of materials and structures. In this work, a hybrid ultrasound based NDT&E method is proposed based on the photoacoustic-laser-source as a noncontact Lamb wave generator by incorporating a line-arrayed patterned candle soot nanoparticle-polydimethylsiloxane (CSNPs-PDMS) patch as the signal amplifier and with a narrow bandwidth. The CSNP-PDMS composite has been investigated as the functional patch for its laser energy absorption efficiency, fast thermal diffusion, and large thermoelastic expansion capabilities. The signal amplitude (in mW) from the CSNP-PDMS patch exhibits 2.3 times higher amplitude than the no patch condition and a narrower bandwidth than other conditions. Furthermore, improvement in the sensitivity is also achieved through the selection of the aluminum nitride sensing system. The overall combination of the Lamb wave generation and receiver-sensing system in this study is found to be very promising for a broad range of noncontact NDT&E applications.
Acoustic transducers↗
Generation of selective single-mode guided waves by d 36 type piezoelectric wafer
In general, mixed modes and dispersion of guided wave occur at any excitation frequency, while single modes are needed for effective nondestructive evaluation of structures. In this work, we present an approach to generate a selective single-mode guided wave in plate-like structures by exploiting the unique directionality of the d 36 type piezoelectric wafer and the symmetry of fundamental guided wave modes. Specifically, we devise a unified fundamental shear horizontal (SH 0 ) wave/fundamental antisymmetric mode (A 0 ) wave directional transducer pair by attaching the d 36 type piezoelectric wafers back to back on the opposite sides of the plate to provide selective, directional single-mode guided waves for actuation and sensing. Originally, the d 36 -type piezoelectric wafer, poled and cut from the lead magnesium niobate-lead titanate crystal, produces a mixture of the in-plane SH 0 (symmetric) mode and out-of-plane A 0 (asymmetric) and S 0 (symmetric) modes. By applying the in-phase or out-of-phase applied electrical field to the coupled d 36 -type piezoelectric wafer pair, our devised approach generates selective single modes, SH 0 or A 0 , respectively, to propagate in the structure. We describe the theoretical development of our approach and conduct both numerical simulations and laboratory experiments for validations.
42 ENGINEERING↗
Quantitative uranium elemental reconstruction using spectral x-ray radiography
X-ray radiography offers the ability to noninvasively inspect the internal structure and material composition of objects. Dual-energy radiography allows material discrimination but is limited in quantitative material measurements due to the broad nature of the interrogating x-ray spectrum. Spectral radiography detectors provide an observation of not just the number of x rays that are transmitted through a sample but also the spectrum. Here, experimental validations of a method to use spectral x-ray radiography to accurately quantify the uranium mass in a powder are presented. An accurate system response model was developed, which includes a model of the incident x-ray source spectrum and a pixel-wise detector response that describes how the transmitted x rays were observed. Further, a calibration to account for the effect of partial x-ray attenuation was developed. As a result, the method is demonstrated to be capable of estimating the uranium mass in a variety of uranium oxide powders to a bias of –0.01±0.62%.
38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
Enhanced resonant ultrasound spectroscopy for measurement of the elastic properties of multi-material systems
Understanding the elastic properties of materials is critical for their safe incorporation and predictable performance. Current methods of bulk elastic characterization often have notable limitations for in situ structural applications, with usage restricted to simple geometries and material distributions. To address these existing issues, this study sought to expand the capabilities of resonant ultrasound spectroscopy (RUS), an established nondestructive evaluation method, to include the characterization of isotropic multi-material samples. In this work, finite-element-based RUS analysis consisted of numerical simulations and experimental testing of composite samples comprised of material pairs with varying elasticity and density contrasts. Utilizing genetic algorithm inversion and mode matching, our results demonstrate that elastic properties of multi-material samples can be reliably identified within several percent of known or nominal values using a minimum number of identified resonance modes, given sample mass is held consistent. The accurate recovery of material properties for composite samples of varying material similarity and geometry expands the pool of viable samples for RUS and advances the method towards in situ inspection and evaluation.
36 MATERIALS SCIENCE↗
Weld procedure produces quality welds for thick sections of Hastelloy-X
Welding program produces premium quality, multipass welds in heavy tube sections of Hastelloy-X. It develops semiautomatic tungsten/inert gas procedures, weld wire procurement specifications material weld properties, welder-operator training, and nondestructive testing inspection techniques and procedures.
Flens, F. J.↗
Dye penetrant for surfaces subsequently contacted by liquid oxygen Patent
Dye penetrant and technique for nondestructive tests of solid surfaces contacted by liquid oxygen
Giles, R. M. F.↗
Quality control of microelectronic wire bonds
Report evaluates ultrasonic bonding of small-diameter aluminum wire joined to ceramic substrates metalized with thin-film and thick-film gold. Quick testing technique for nondestructive location of poor wire bonds is also presented.
Thiel, R. A.↗
High Resolution Millimeter Wave Inspecting of the Orbiter Acreage Heat Tiles of the Space Shuttle
Presence of defects such as disbonds, delaminations, impact damage, in thermal protection systems can significantly reduce safety of the Space Shuttle and its crew. The physical cause of Space Shuttle Columbia's catastrophic failure was a breach in its thermal protection system, caused by a piece of external tank insulating foam separating from the external tank and striking the leading edge of the left wing of the orbiter. There is an urgent need for a rapid, robust and life-circle oriented nondestructive testing (NDT) technique capable of inspecting the external tank insulating foam as well as the orbiter's protective (acreage) heat tiles and its fuselage prior and subsequent to a launch. Such a comprehensive inspection technique enables NASA to perform life-cycle inspection on critical components of the orbiter and its supporting hardware. Consequently, NASA Marshall Space Flight Center initiated an investigation into several potentially viable NDT techniques for this purpose. Microwave and millimeter wave NDT methods have shown great potential to achieve these goals. These methods have been successfully used to produce images of the interior of various complex, thick and thin external tank insulating foam structures for real focused reflectometer at operating frequency from 50-100 GHz and for synthetic aperture techniques at Ku-band (12-18 GHz) and K-band (18-26 GHz). Preliminary results of inspecting heat tile specimens show that increasing resolution of the measurement system is an important issue. This paper presents recent results of an investigation for the purpose of detecting anomalies such as debonds and corrosion in metal substrate in complex multi-sectioned protective heat tile specimens using a real focused 150 GHz (D-band) reflectometer and wide-band millimeter wave holography at 33-50, GHz (Q-band).
Case, J. T.↗
Reducing Aviation Fuel Costs with Non-Destructive Testing
Thermal barrier coatings (TBCs) are absolutely critical to the efficient and safe operation of gas turbine engines (GTEs). Manufacturing TBCs is a complex chemical, thermal and mechanical process that requires precise control. And yet, the variation in life of a TBC operated within a GTE is large. This variation ultimately reduces operational performance via a designed reduction to the turbine entry temperature, T4.This paper makes the case for developing advanced THz and sub-millimeter based nondestructive testing (NDT) techniques, capable of estimating when TBC components will fail. Such a technique could identify TBCs with low expected remaining useful lifetimes, directly after production. These TBCs could be re-manufactured, thereby not only improving their own expected useful life, but also the mean lifetime of the entire manufacturing population. A series of calculations demonstrates that TBCs with enhanced life characteristics can withstand higher T4 temperatures. Assuming that a GTE is to operate at a constant thrust, this increased temperature can be traded for a reduction in fuel flow. An analysis comparing fuel savings to manufacturing costs shows that substantial savings are achievable.
microwaves↗