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DOE OSTI2021

A Computed Tomography Automation Architecture Developed from a Comprehensive Literature Review

This paper presents a literature review on techniques related to the computed tomography procedure that incorporate automation elements in their research investigations or industrial applications. Computed tomography (CT) is a non-destructive testing (NDT) technique in that the imaging and inspection are performed without damaging the sample, allowing for additional or repeated analysis if necessary. The reviewed literature is organized based on the steps associated with a general NDT task in order to define an end-to-end computed tomography automation architecture. The process steps include activities prior to image collection, during the scan, and after the data are collected. It further reviews efforts related to repeating this process based on a previous scan result. By analyzing the multiple existing but disparate efforts found in the literature, we present a framework for fully automating NDT procedures and discuss the remaining technical gaps in the developed framework.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1993

Investigation of Zerodur material processing

The Final Report of the Center for Applied Optics (CAO), of The University of Alabama (UAH) study entitled 'Investigation of Zerodur Material Processing' is presented. The objectives of the effort were to prepare glass samples by cutting, grinding, etching, and polishing block Zerodur to desired specifications using equipment located in the optical shop located in the Optical System Branch at NASA/MSFC; characterize samples for subsurface damage and surface roughness; utilize Zerodur samples for coating investigations; and perform investigations into enhanced optical fabrication and metrology techniques. The results of this investigation will be used to support the Advanced X Ray Astrophysics Facility (AXAF) program as well as other NASA/MSFC research programs. The results of the technical effort are presented and discussed.

Johnson, R. Barry↗

NASA NTRS2004

Durability Assessment of Gamma Tial

Gamma TiAl was evaluated as a candidate alloy for low-pressure turbine blades in aeroengines. The durability of g-TiAl was studied by examining the effects of impact or fretting on its fatigue strength. Cast-to-size Ti-48Al-2Cr-2Nb was studied in impact testing with different size projectiles at various impact energies as the reference alloy and subsequently fatigue tested. Impacting degraded the residual fatigue life. However, under the ballistic impact conditions studied, it was concluded that the impacts expected in an aeroengine would not result in catastrophic damage, nor would the damage be severe enough to result in a fatigue failure under the anticipated design loads. In addition, other gamma alloys were investigated including another cast-to-size alloy, several cast and machined specimens, and a forged alloy. Within this Ti-48-2-2 family of alloys aluminum content was also varied. The cracking patterns as a result of impacting were documented and correlated with impact variables. The cracking type and severity was reasonably predicted using finite element models. Mean stress affects were also studied on impact-damaged fatigue samples. The fatigue strength was accurately predicted based on the flaw size using a threshold-based, fracture mechanics approach. To study the effects of wear due to potential applications in a blade-disk dovetail arrangement, the machined Ti-47-2-2 alloy was fretted against In-718 using pin-on-disk experiments. Wear mechanisms were documented and compared to those of Ti-6Al-4V. A few fatigue samples were also fretted and subsequently fatigue tested. It was found that under the conditions studied, the fretting was not severe enough to affect the fatigue strength of g-TiAl.

Draper, Susan L.↗

NASA NTRS2005

Infrared On-Orbit RCC Inspection With the EVA IR Camera: Development of Flight Hardware From a COTS System

In November 2004, NASA's Space Shuttle Program approved the development of the Extravehicular (EVA) Infrared (IR) Camera to test the application of infrared thermography to on-orbit reinforced carbon-carbon (RCC) damage detection. A multi-center team composed of members from NASA's Johnson Space Center (JSC), Langley Research Center (LaRC), and Goddard Space Flight Center (GSFC) was formed to develop the camera system and plan a flight test. The initial development schedule called for the delivery of the system in time to support STS-115 in late 2005. At the request of Shuttle Program managers and the flight crews, the team accelerated its schedule and delivered a certified EVA IR Camera system in time to support STS-114 in July 2005 as a contingency. The development of the camera system, led by LaRC, was based on the Commercial-Off-the-Shelf (COTS) FLIR S65 handheld infrared camera. An assessment of the S65 system in regards to space-flight operation was critical to the project. This paper discusses the space-flight assessment and describes the significant modifications required for EVA use by the astronaut crew. The on-orbit inspection technique will be demonstrated during the third EVA of STS-121 in September 2005 by imaging damaged RCC samples mounted in a box in the Shuttle's cargo bay.

Gazanik, Michael↗

NASA NTRS2018

Structural Certification of Human-Rated Inflatable Space Structures

This paper details the results of an initial study to develop a certification plan for human-rated inflatable space structures, including guidelines for qualification testing. Habitable softgoods inflatables are multi-layered shell structures that use high-strength webbing, cordage and broadcloth fabric to carry the skin loads of a variety of volumetric shapes and structural architectures. The primary objectives of this study are to define the key parameters that affect these structures and propose a statistically robust approach to defining safety and knockdown factors based on test and analysis. Current NASA standards for habitable inflatable space structures use a factor of safety of 4, which was inherited from airship design criteria. An updated approach to defining a design factor, taking into account material strength variability, load variability in the article, number of test samples, and damage and degradation effects is specified. Accurate analytical modeling of these structures is hindered by the difficulty of obtaining accurate and consistent material data due to load-history- dependent, nonlinear load versus strain behavior. A building block approach to certification is detailed that uses stochastic modeling and statistical test design and analysis to address the unique challenges these high-strength softgoods structures present. Human-rated inflatable modules are a transformative capability for launching much larger habitable volumes into space than is possible with rigid shell structures. This research aims to provide the framework for certifying these structures for future human space exploration missions.

Jones, Thomas C.↗

NASA NTRSDate not supplied

On-Orbit Glass Stress Measurement Tool Development

Exposed window surfaces on-orbit are vulnerable to a variety of damage including impacts. These impacts impart stress into the panes and reduce the remaining life of the window. Spacecraft windows are evaluated before and after flight to determine the minimum strength of the glass prior to launch. Currently, no method exists to accurately evaluate the windows on-orbit. An on-orbit optical system is under development to evaluate spacecraft windowpane material for remaining flight life by directly measuring the stress in the glass. This optical system builds on the industry-standard practice of calculating the amount of impact-induced stress through birefringence measurement. In industry, the birefringence is imaged through the pane with a detector and light source on opposite sides. On-orbit, there is only access to one side of the pane. This system has been designed to image birefringence by reflecting the light off the pane to a detector on the same side of the glass. Previous studies have shown a correlation between material stress distribution and the associated K-value. This system is designed to determine low strength areas which can be caused by defects due to impact damage. Glass samples will be imaged and broken in order to correlate impact-induced stress to the fracture strength of the material. Once this correlation is determined, a quantitative assessment of the stress areas in spacecraft windows will occur prior to and during mission operations to reliably determine the overall strength of the glass.

Max J Schneiderman↗

NASA NTRS1974

Study of radiation damage and structure of Luna 16 sample particles using high-resolution electron microscopes

Using an electron scanning microscope and a high voltage microscope, a study was made of the radiation damage and structure of micron sized grains and grains separated from the 200-mesh fraction of the L-16-19 surface material sample. Then the structural features were compared with those found by studying with the same techniques grains separated from 20 different samples of lunar dust taken from the Apollo 11, Apollo 12, Apollo 14, and Apollo 15 collections. The L-16-19 sample is similar to the most intensely irradiated samples returned to earth by Apollo craft.

Borg, J.↗

NASA NTRS2005

Application of Ultrasonic Guided Waves for Evaluating Aging Wire Insulation

Aging wiring has become a critical issue to the aerospace and aircraft industries due to Shuttle and aircraft incidents. The problem is that over time the insulation on wire becomes brittle and cracks. This exposes the underlying conductive wire to the potential for short circuits and fire. Popular methods of monitoring aging wire problems focuses on applying electrical sensing techniques that are sensitive to the conductor's condition, but not very sensitive to the wire insulation's condition. Measurement of wire insulation stiffness and ultrasonic properties by ultrasonic guided waves is being examined. Experimental measurements showed that the lowest order extensional mode could be sensitive to stiffness changes in the wire insulation. To test this theory conventional wire samples were heat damaged in an oven, in a range of heating conditions. The samples were 12, 16, and 20 gauge and the heat damage introduced material changes in the wire insulation that made the originally flexible insulation brittle and darker in color. Results showed that extensional mode phase velocity increased for the samples that were exposed to heat for longer duration.

Anastasi, Robert F.↗

DOE OSTI2024

Development and Integration of a Stochastic Clad Damage Propagation Model into PRONGHORN-SC Subchannel Analysis Code

The failure of fuel pins in nuclear reactors is intrinsically stochastic. Typically, a combination of variation in manufacturing that affects the material characteristics and the fuel assembly dimensions, variation in operating conditions, such as local power, coolant flow rate, and irradiation induced changes in material properties lead to a large uncertainty in failure margin of the fuel pins. Failure, therefore, may occur in exceptional pins with adverse combinations of these variations. Upon a metal fuel pin (U-Pu-Zr/HT9) failure, depressurization of the fuel pin takes place by release of fission gas, liquid sodium bond, and potentially solid fuel particles or molten/eutectic fuel droplets through the hole in cladding. The effect of a fission gas jet on neighbor fuel pins and possible propagation of a clad damage during normal operation was studied experimentally in 1970s and it was found that the post-failure fission gas jet insulates the jet impingement area of the target fuel pin surface and could increase the target pin’s surface temperature by as much as 100 – 200 K during the failed pin depressurization. It was concluded that the effect should not lead to fuel pin failure propagation during normal operation. In accident scenarios of sodium and lead fast reactors such as Unprotected Loss-Of-Flow (ULOF) or Unprotected Transient Over Power (UTOP), the fuel pins can be subjected to higher clad temperatures and fuel pin pressures or fuel clad mechanical/chemical interaction where thermal creep margin becomes significantly lower compared to the normal operation conditions. Therefore, possible stochastic failure and the post-failure fission gas/fuel jet impingement could be critical in order to predict fuel pin failure propagation. Pin depressurization due to fission gas release may degrade the heat transfer by formation of a gas blanket on a neighboring pin surface, which is a local phenomenon, and by causing coolant flow deceleration and starvation, which could affect a surrounding region as well. Furthermore, the potential presence of solid fuel particles or molten fuel at the time of clad failure could boost post-failure jet induced degradation even further. The present study models the U-Pu-Zr/HT9 metal fuel pin failure and stochastic clad damage propagation by biased sampling based on a Cumulative Damage Fraction (CDF) type clad failure criterion and the normal distribution of fuel failure probability density as a function of logarithm of Cumulative Damage Fraction. In addition, the effect of post-failure fission gas jet on heat transfer degradation is modeled for the target pins. This model is called stochastic Clad Damage Propagation (CDAP). The CDAP model is now fully integrated into developmental version of PRONGHORN-SC subchannel analysis code, allowing for modeling local failures and its propagation potential. Section 2 describes the components of the CDAP models. Section 3 describes the model implementation to PRONGHORN-SC and input specifications. Section 4 describes the CDAP model validation coupled to PRONGHORN-SC.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Dynamic properties of 316l stainless steel repaired using electron beam additive manufacturing

Additive manufacturing has the potential to be used for repair of high-value parts, but the strength and integrity of such repaired parts, especially under dynamic loading, in still unknown. This work presents the results of high strain-rate dynamic testing of additively repaired stainless steel samples. The 316L samples were intentionally damaged and subsequently repaired with 308L stainless steel wire using electron beam additive manufacturing. The repaired samples were subjected to gas-gun impact testing to induce incipient damage and determine the role played by the repaired region in dictating damage and failure. The results show the following: 1) the equation of state of the repaired region is comparable to the original material as shown by the unchanged spall plane location, 2) the deformation behavior is similar to the original material as shown by the similar Hugoniot Elastic limit, 3) the spall strength of the repaired region is slightly higher than the original material due to varying grain size, and 4) the damage morphology in the repaired region is different and involves a high rate of void coalescence. In conclusion, despite these minor differences in the spall strength and the damage morphology, the overall dynamic response of the original material and repaired samples is similar suggesting that AM is a promising approach for repairing high-value components.

36 MATERIALS SCIENCE↗

NASA NTRS1983

The Antaeus Project - An orbital quarantine facility for analysis of planetary return samples

A design is presented for an earth-orbiting facility for the analysis of planetary return samples under conditions of maximum protection against contamination but minimal damage to the sample. The design is keyed to a Mars sample return mission profile, returning 1 kg of documented subsamples, to be analyzed in low earth orbit by a small crew aided by automated procedures, tissue culture and microassay. The facility itself would consist of Spacelab shells, formed into five modules of different sizes with purposes of power supply, habitation, supplies and waste storage, the linking of the facility, and both quarantine and investigation of the samples. Three barriers are envisioned to protect the biosphere from any putative extraterrestrial organisms: sealed biological containment cabinets within the Laboratory Module, the Laboratory Module itself, and the conditions of space surrounding the facility.

Sweet, H. C.↗

DOE OSTI2022

Reduced defect recovery in self-ion damaged W due to simultaneous deuterium exposure during annealing

Deuterium (D) plasma exposure during annealing of self-ion damaged tungsten (W) is shown to exhibit reduced defect recovery when compared to annealing without D plasma exposure. In these experiments, samples were first damaged with 20 MeV W ions. Next, samples were annealed either with or without simultaneous D 2 plasma exposure. The simultaneous annealed samples were first decorated by D 2 plasma at 383 K prior to ramping up to an annealing temperature of 473, 573, 673, or 773 K and held for 1 h with concurrent plasma exposure. The vacuum annealed samples each had a corresponding temperature history but without D 2 plasma treatment. Finally, all samples were exposed to D 2 plasma at 383 K to decorate any remaining defects. Nuclear reaction analysis and thermal desorption spectroscopy (TDS) shows that the simultaneous plasma-exposed and annealed samples exhibited virtually no defect recovery at annealing temperatures of up to 673 K, and had higher D retention than found in the vacuum annealed samples. TDS results indicate that only the lowest detrapping energy defects recover at an 773 K anneal for the simultaneous plasma annealed samples, while the vacuum annealed samples showed defect recovery at all anneal temperatures. Furthermore, this experiment clearly demonstrates that D occupied defects can significantly reduce or eliminate defect annealing in W, and is consistent with the existence of synergistic plasma exposure/displacement damage effects in fusion-energy relevant plasma facing materials.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Modelling yield cap evolution in sandstone based on brittle creep experiments

The Zenifim Formation is being considered as a potential disposal formation for a deep borehole nuclear repository concept in Israel. Site selection and repository construction are intended to ensure that waste is separated from circulating groundwater, but long-term deformation of the wellbore could potentially create fluid flow pathways. To understand how time-dependent rock strength could affect wellbore stability, here we conducted creep tests under low to moderate confining pressures on retrieved core from the Zenifim formation. During creep, samples strain slowly as gradual damage accumulation progressively weakens the samples. Failure eventually occurred through the near-instantaneous formation of a shear fracture. Experimental results were used to calibrate a continuum damage poro-elastic model for sandstones. The calibrated damage-poro-elastic model successfully simulates different types of loading experiments including quasi-static and creep. The state of strain in experiments is close to yield during loading as the yield cap continuously evolves with damage accumulation. For creep tests, most damage occurs during triaxial loading. Minor damage accumulation occurs under constant load until the final stage of creep, where damage accelerates and promotes unstable fracturing.

58 GEOSCIENCES↗

DOE OSTI2023

Spall strength of additively repaired 304L stainless steel

Additive manufacturing has the potential to repair damaged parts, but the performance of additive materials under high strain rate loading is still uncertain—especially with the added complexity of an interface with an existing wrought material. In this work, 304L stainless steel samples were intentionally damaged and then repaired with wire-fed laser additive manufacturing. The samples were subjected to shock loading to generate incipient spall. Velocimetry and post-mortem metallography results show that when the additive repair process parameters are optimized to reduce porosity and match the equation of state of the original material, the influence of the repair region on the shock propagation is negligible. In conclusion, the free-surface velocity profile and internal damage morphology of the repaired sample are shown to be practically identical to the pristine material.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Effects of neutron irradiation on hydrogen isotope permeation on W-Re

Hydrogen and deuterium permeation behavior for neutron damaged W and W-3 %Re was evaluated using a Plasma Driven Permeation device. For neutron damaged W-3 %Re at 773 K and 1473 K, precipitation of Re and Os was observed by atom probe tomography. Neutron irradiation introduced defect damage throughout the sample and enhanced H and D diffusion toward downstream side. The existence of irradiation damage by neutron irradiation was found to increase hydrogen isotope permeation. Moreover, the existence of Re has suppressed the formation of irradiation defects for hydrogen isotope trapping sites. Further, the recovery of irradiation defects by increasing the irradiation temperature led to the structural changes due to the diffusion of Re and Os, which also affected the hydrogen isotope permeation behavior.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRSDate not supplied

Determining Surface Exposure Ages of Regolith Grains in Lunar Core Sample 73002 By Investigating Solar Particle Irradiation Damage

Space weathering causes the surface soils of airless bodies like the Moon to be micro-structurally and chemically altered by exposure to micrometeoroid bombardment and solar wind irradiation. These alterations accumulate in surface grains with continued residence in the uppermost millimeters of regolith. Low energy solar wind ions (largely H+ and He+) produce a layer of radiation damage as they become implanted in grain surfaces. Also present are solar energetic particle (SEP) tracks, which are nanoscale lineations within grain interiors formed by heavy, high-energy ions (mainly Fe group nuclei) penetrating up to millimeters below the surface. Recent work has determined that the width of solar wind-damaged rims on anorthite and olivine, and their respective SEP track densities are correlated with each other and with grain surface exposure age. Core sample 73002, recently released under the Apollo Next Generation Sample Analysis (ANGSA) Program, has provided an opportunity to study material collected from the light mantle formation in the Taurus-Littrow Valley during Apollo 17. The light mantle is thought to have been deposited vial and slide originating from the neighboring South Massif. Spectral analysis of bulk core soils found a plagioclase rich composition, confirming a highlands origin of the formation. Spectral profiles and ferromagnetic resonance (FMR) measurements of bulk soils sampled at cm-intervals from 73002 indicate that regolith up to~9.5 cm in depth have maturity indices consistent with longer durations of surface processing than samples deeper in the core. Thus, this upper ~9 cm layer likely represents the maximum extent of an in-situ reworking zone which may have persisted over 5 to 17million years. Here we present an analysis of grain exposure ages within the in-situ reworking zone of 73002derived from SEP track density measurements via transmission electron microscopy.

J A McFadden↗

DOE OSTI2020

Current measurements in the intermittent-contact mode of atomic force microscopy using the Fourier method: a feasibility analysis

Atomic force microscopy (AFM) is an important tool for measuring a variety of nanoscale surface properties, such as topography, viscoelasticity, electrical potential and conductivity. Some of these properties are measured using contact methods (static contact or intermittent contact), while others are measured using noncontact methods. Some properties can be measured using different approaches. Conductivity, in particular, is mapped using the contact-mode method. However, this modality can be destructive to delicate samples, since it involves continuously dragging the cantilever tip on the surface during the raster scan, while a constant tip–sample force is applied. In this paper we discuss a possible approach to develop an intermittent-contact conductive AFM mode based on Fourier analysis, whereby the measured current response consists of higher harmonics of the cantilever oscillation frequency. Such an approach may enable the characterization of soft samples with less damage than contact-mode imaging. To explore its feasibility, we derive the analytical form of the tip–sample current that would be obtained for attractive (noncontact) and repulsive (intermittent-contact) dynamic AFM characterization, and compare it with results obtained from numerical simulations. Although significant instrumentation challenges are anticipated, the modelling results are promising and suggest that Fourier-based higher-harmonics current measurement may enable the development of a reliable intermittent-contact conductive AFM method.

14 SOLAR ENERGY↗

NASA NTRS1992

Contamination of optical surfaces in Earth orbit

Glass and glass ceramic samples exposed to the low earth orbit environment for approximately 5.5 years on the Long Duration Exposure Facility (LDEF) were found to display limited degradation in optical transmission. Commercial optical quality fused silica samples display decreases in transmission in the 200 to 400 nm wavelength region, and this degradation appears to be a consequence of surface contamination. The contamination, found only on internal surfaces of samples, was measured by medium energy backscattering spectrometry and found to be primarily carbon. Additional thin film contamination by a species with atomic mass near 64, which was present at the level of about 8 x 10 exp 14/sq. cm has not been identified. These observations are consistent with the interpretation that organic binders used in the black absorbing paint (Chem Glaze Z-306) inside the sample holding tray were concentrated in the vicinity of the samples and photolytically cracked by solar UV radiation. The resulting decomposition products were deposited on the interior sample surface and gave rise to the optical transmission loss. No detectable contamination was observed on the external or space exposed surface of the samples. No measurable damage was detected which could be attributed to the direct action of gamma or UV radiation on the glass samples. These results emphasize the need for special precautions in the preparation of spacecraft carrying precision optical components on long duration missions.

Donald L Kinser↗