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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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88 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

A Model-Based, Bayesian Solution for Characterization of Complex Damage Scenarios in Aerospace Composite Structures

Ultrasonic damage detection and characterization is commonly used in nondestructive evaluation (NDE) of aerospace composite components. In recent years there has been an increased development of guided wave based methods. In real materials and structures, these dispersive waves result in complicated behavior in the presence of complex damage scenarios. Model-based characterization methods utilize accurate three dimensional finite element models (FEMs) of guided wave interaction with realistic damage scenarios to aid in defect identification and classification. This work describes an inverse solution for realistic composite damage characterization by comparing the wavenumber-frequency spectra of experimental and simulated ultrasonic inspections. The composite laminate material properties are first verified through a Bayesian solution (Markov chain Monte Carlo), enabling uncertainty quantification surrounding the characterization. A study is undertaken to assess the efficacy of the proposed damage model and comparative metrics between the experimental and simulated output. The FEM is then parameterized with a damage model capable of describing the typical complex damage created by impact events in composites. The damage is characterized through a transdimensional Markov chain Monte Carlo solution, enabling a flexible damage model capable of adapting to the complex damage geometry investigated here. The posterior probability distributions of the individual delamination petals as well as the overall envelope of the damage site are determined.

H. Reed↗
NASA NTRS2013

3D Guided Wave Motion Analysis on Laminated Composites

Ultrasonic guided waves have proved useful for structural health monitoring (SHM) and nondestructive evaluation (NDE) due to their ability to propagate long distances with less energy loss compared to bulk waves and due to their sensitivity to small defects in the structure. Analysis of actively transmitted ultrasonic signals has long been used to detect and assess damage. However, there remain many challenging tasks for guided wave based SHM due to the complexity involved with propagating guided waves, especially in the case of composite materials. The multimodal nature of the ultrasonic guided waves complicates the related damage analysis. This paper presents results from parallel 3D elastodynamic finite integration technique (EFIT) simulations used to acquire 3D wave motion in the subject laminated carbon fiber reinforced polymer composites. The acquired 3D wave motion is then analyzed by frequency-wavenumber analysis to study the wave propagation and interaction in the composite laminate. The frequency-wavenumber analysis enables the study of individual modes and visualization of mode conversion. Delamination damage has been incorporated into the EFIT model to generate "damaged" data. The potential for damage detection in laminated composites is discussed in the end.

Tian, Zhenhua↗
NASA NTRSDate not supplied

Design for Inspection: A Formalized Approach to Evaluating the Inspectability of Aerospace Structures Early in the Design Process

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 structure can be determined early in the design cycle, these challenging inspection scenarios can be avoided. Therefore, there exists a need for a resource friendly formalized approach to gauge the inspectability of a structure. This paper proposes the use of a novel inspectability metric to meet this need. The inspectability metric is a standardized, automation friendly procedure that uses simulations to determine inspectability. It 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. In this preliminary study, we will demonstrate how the inspectability metric is able to determine the inspectability of a structure as a function of changes in the structure’s design.

Peter Juarez↗
NASA NTRS2000

Virtual Reality Robotic Operation Simulations Using MEMICA Haptic System

There is an increasing realization that some tasks can be performed significantly better by humans than robots but, due to associated hazards, distance, etc., only a robot can be employed. Telemedicine is one area where remotely controlled robots can have a major impact by providing urgent care at remote sites. In recent years, remotely controlled robotics has been greatly advanced. The robotic astronaut, "Robonaut," at NASA Johnson Space Center is one such example. Unfortunately, due to the unavailability of force and tactile feedback capability the operator must determine the required action using only visual feedback from the remote site, which limits the tasks that Robonaut can perform. There is a great need for dexterous, fast, accurate teleoperated robots with the operator?s ability to "feel" the environment at the robot's field. Recently, we conceived a haptic mechanism called MEMICA (Remote MEchanical MIrroring using Controlled stiffness and Actuators) that can enable the design of high dexterity, rapid response, and large workspace system. Our team is developing novel MEMICA gloves and virtual reality models to allow the simulation of telesurgery and other applications. The MEMICA gloves are designed to have a high dexterity, rapid response, and large workspace and intuitively mirror the conditions at a virtual site where a robot is simulating the presence of the human operator. The key components of MEMICA are miniature electrically controlled stiffness (ECS) elements and Electrically Controlled Force and Stiffness (ECFS) actuators that are based on the sue of Electro-Rheological Fluids (ERF). In this paper the design of the MEMICA system and initial experimental results are presented.

NDE NDT composite materials defects inspection↗
NASA NTRS2012

Time-Domain Terahertz Computed Axial Tomography NDE System

NASA has identified the need for advanced non-destructive evaluation (NDE) methods to characterize aging and durability in aircraft materials to improve the safety of the nation's airline fleet. 3D THz tomography can play a major role in detection and characterization of flaws and degradation in aircraft materials, including Kevlar-based composites and Kevlar and Zylon fabric covers for soft-shell fan containment where aging and durability issues are critical. A prototype computed tomography (CT) time-domain (TD) THz imaging system has been used to generate 3D images of several test objects including a TUFI tile (a thermal protection system tile used on the Space Shuttle and possibly the Orion or similar capsules). This TUFI tile had simulated impact damage that was located and the depth of damage determined. The CT motion control gan try was designed and constructed, and then integrated with a T-Ray 4000 control unit and motion controller to create a complete CT TD-THz imaging system prototype. A data collection software script was developed that takes multiple z-axis slices in sequence and saves the data for batch processing. The data collection software was integrated with the ability to batch process the slice data with the CT TD-THz image reconstruction software. The time required to take a single CT slice was decreased from six minutes to approximately one minute by replacing the 320 ps, 100-Hz waveform acquisition system with an 80 ps, 1,000-Hz waveform acquisition system. The TD-THZ computed tomography system was built from pre-existing commercial off-the-shelf subsystems. A CT motion control gantry was constructed from COTS components that can handle larger samples. The motion control gantry allows inspection of sample sizes of up to approximately one cubic foot (.0.03 cubic meters). The system reduced to practice a CT-TDTHz system incorporating a COTS 80- ps/l-kHz waveform scanner. The incorporation of this scanner in the system allows acquisition of 3D slice data with better signal-to-noise using a COTS scanner rather than the gchirped h scanner. The system also reduced to practice a prototype for commercial CT systems for insulating materials where safety concerns cannot accommodate x-ray. A software script was written to automate the COTS software to collect and process TD-THz CT data.

Zimdars, David↗
NASA NTRS2019

Computational Non-Destructive Evaluation Improving Ultrasonic Interrogation of Complex Geometry Composite Parts

Finite element simulation was employed in modeling the ultrasound (UT) pressure pulse propagation through a coupled liquid-composite medium to reproduce experimental data. From the simulation point of view, the proposed approach is challenging when there is a large simulation domain. For example, it is shown that a sub-micron wavelength of an ultrasonic wave requires a mesh size of several microns and this in turn requires significant computational resources, as well as special care in modeling. Some of the simulation results are presented considering that such modeling should reproduce experimental data for a healthy and faulty composite structure with complex geometry. Many possible experimental setups are simulated to demonstrate the non-destructive testing technique. This setup includes the generation of pressure pulse propagating through the tested composite plate and possible scattering by discontinuities (area of different impedance) that may be present in the panel. This scattered pulse together with the baseline pressure pulse generates a signature on the probe element which can be used to locate the position of defects in the structures.

modeling↗
NASA NTRSDate not supplied

Assessing Risk Due to Small Sample Size in Probability of Detection Analysis Using Tolerance Intervals

Small sample size (e.g.6-30) poses risk in results of probability of detection (POD) analysis using tolerance intervals. This method is also called as the limited sample or LS POD. The analysis is performed either during NDE procedure qualification or for assessment of reliability of an NDE procedure. The risk is primarily due to sampling error. Smaller samples are not likely to be random to the population or representative of the population. The small samples are likely to be biased. Biased samples have smaller standard deviation compared to the population. POD analysis with small biased sample can lead to overestimation of POD. Many sampling schemes are available in statistics to mitigate sampling risk. Primary objective of POD analysis is to determine a decision threshold from signal response measurements of a sample such that it is less than or equal to population decision threshold for 90% POD. Sampling error implies that this NDE reliability condition is violated. One of sampling types is called a representative sample. Representative samples reduce variance in POD estimates but also reduce magnitude of the error. Sampling sensitivity analysis for some sampling types is performed here using repetitive random sampling or Monte Carlo method. Six sampling types are considered for comparison. Some of the sampling types are similar to drawing a representative sample. LS POD model assumes random sampling. Therefore, random sampling is used as a basis for comparison with each sampling type. The sampling types used in the analysis are, A. Nominal and worst-case sampling, B. Worst-case sampling, C. Nominal case sampling, D. Random sampling, E. Random target, and sub-target sampling. F. Nominal target and sub-target sampling. Results of Monte Carlo simulation indicate that type F sampling can mitigate sampling risk and is also more practical to implement. Type A sampling may also mitigate the sampling risk, but it may be less practical to implement.

Ajay M Koshti↗
NASA NTRS1997

Fatigue Reliability of Gas Turbine Engine Structures

The results of an investigation are described for fatigue reliability in engine structures. The description consists of two parts. Part 1 is for method development. Part 2 is a specific case study. In Part 1, the essential concepts and practical approaches to damage tolerance design in the gas turbine industry are summarized. These have evolved over the years in response to flight safety certification requirements. The effect of Non-Destructive Evaluation (NDE) methods on these methods is also reviewed. Assessment methods based on probabilistic fracture mechanics, with regard to both crack initiation and crack growth, are outlined. Limit state modeling techniques from structural reliability theory are shown to be appropriate for application to this problem, for both individual failure mode and system-level assessment. In Part 2, the results of a case study for the high pressure turbine of a turboprop engine are described. The response surface approach is used to construct a fatigue performance function. This performance function is used with the First Order Reliability Method (FORM) to determine the probability of failure and the sensitivity of the fatigue life to the engine parameters for the first stage disk rim of the two stage turbine. A hybrid combination of regression and Monte Carlo simulation is to use incorporate time dependent random variables. System reliability is used to determine the system probability of failure, and the sensitivity of the system fatigue life to the engine parameters of the high pressure turbine. 'ne variation in the primary hot gas and secondary cooling air, the uncertainty of the complex mission loading, and the scatter in the material data are considered.

Cruse, Thomas A.↗
NASA NTRS2010

Investigating Premature Ignition of Thruster Pressure Cartridges by Vibration-Induced Electrostatic Discharge

Pyrotechnic thruster pressure cartridges (TPCs) are used for aeroshell separation on a new NASA crew launch vehicle. Nondestructive evaluation (NDE) during TPC acceptance testing indicated that internal assemblies moved during shock and vibration testing due to an internal bond anomaly. This caused concerns that the launch environment might produce the same movement and release propellant grains that might be prematurely ignited through impact or through electrostatic discharge (ESD) as grains vibrated against internal surfaces. Since a new lot could not be fabricated in time, a determination had to be made as to whether the lot was acceptable to fly. This paper discusses the ESD evaluation and a separate paper addresses the impact problem. A challenge to straight forward assessment existed due to the unavailability of triboelectric data characterizing the static charging characteristics of the propellants within the TPC. The approach examined the physical limitations for charge buildup within the TPC system geometry and evaluated it for discharge under simulated vibrations used to qualify components for launch. A facsimile TPC was fabricated using SS 301 for the case and surrogate worst case materials for the propellants based on triboelectric data. System discharge behavior was evaluated by applying high voltage to the point of discharge in air and by placing worst case charge accumulations within the facsimile TPC and forcing discharge. The facsimile TPC contained simulated propellant grains and lycopodium, a well characterized indicator for static discharge in dust explosions, and was subjected to accelerations equivalent to the maximum accelerations possible during launch. The magnitude of charge generated within the facsimile TPC system was demonstrated to lie in a range of 100 to 10,000 times smaller than the spark energies measured to ignite propellant grains in industry standard discharge tests. The test apparatus, methodology, and results are described in this paper.

Woods, Stephen S.↗
NASA NTRSDate not supplied

Investigating Laser Beam Welding as an In-Space Joining Technique via Thermal Vacuum and Microgravity and Vacuum Experiments

In-space joining technologies are crucial for stimulating an in-space economy and for enabling sustained space exploration by in-space manufacturing and repair of metallic structures. Compared to brazing or soldering, in-space welding (ISW) can provide highly hermetic, strong, and complex joints, potentially without introducing additional material. However, the influence of extreme temperatures, reduced pressure, and reduced gravity on ISW is not yet fully elucidated. Several efforts at NASA are investigating laser beam welding (LBW) as a joining and repair method in both thermal vacuum (TVAC) and combined vacuum & reduced gravity environments. NASA Marshall Space Flight Center (MSFC) shepherded several ISW projects in its past, including the 1973 electron beam welding on Skylab, the 1989 low-power LBW on parabolic flights, and the unflown 1990s-era In-Space Welding Experiment. Recent parabolic flights and 3 degree-of-freedom ground testing build upon this heritage. A collaboration with the Ohio State University using NASA Langley Research Center (LaRC) hardware retrofitted for LBW achieved the first high-powered laser welds under vacuum and low gravity and developed a workforce capable developing such experimental hardware. A ground testing campaign at the MSFC Flat Floor simulated fit-up and welding representative of ISW in 3 degrees of freedom to emulate microgravity effects on inertial systems. One ongoing effort is a NASA Early Career Initiative project – Lunar Assembly and Servicing by Autonomous Robotics (LASAR). Ruggedized LBW components were developed by an external partner for use in TVAC. A TVAC-rated robotic arm was procured by MSFC and used in the first known robotic laser weld where all components save the laser generator were under vacuum. NASA Johnson Space Center (JSC) is advancing supervised autonomy of ISW. NASA LaRC continues to adapt their unique snowflake joint geometry, suitable for connecting segments in trusses and other structures, to LBW. Upcoming TVAC campaigns will focus on testing extreme temperatures, proving out autonomous operations, and demonstrating weld repair. Weld inspection will occur via a non-contact nondestructive evaluation (NDE) technique – electromagnetic acoustic transduction (EMAT). Another ongoing effort based at MSFC is the DISCMAN -- DIsk-Shaped Configurable and Modular vAcuum uNit – which seeks to development a compact, modular payload that can provide a vacuum environment while in a reduced gravity condition. This payload could support multiple in-space manufacturing developmental efforts, with the first demonstration technology being LBW. Currently, the design is targeting operations in the pressurized volume of a space station, but the payload could readily be adapted to other flight platforms such as parabolic or even suborbital vehicles. LASAR elucidates the effects of temperature and vacuum on LBW while DISCMAN probes those of vacuum and gravity. Through these complementary efforts, NASA is addressing the primary challenges of ISW across the space environment while simultaneously developing and maturing technologies including robotic systems and inspection methodologies for future practical implementation on the Moon and beyond. This approach is timely, as upcoming missions requiring sustained human presence in space will depend on reliable ISW capabilities to create robust metallic joints currently unproven in the space environment and to perform repairs in situ .

hypogravity↗
NASA NTRS1997

Laser Shearographic Inspection for Debonds in Sprayed On Foam Insulation (SOFI)

Preliminary results of shearographic inspections of the test panels simulating the Space Shuttle's external tank (ET) spray on foam insulation (SOFI) are presented. Debonding of SOFI may introduce flight debris that may damage the orbiter's thermal protection system (TPS) exposing the orbiter (as well as the ET) to thermal loading. It is estimated that 90 percent of the TPS damage on the orbiter's 'belly' results from debonded SOFI during ascent. A series of test panels were fabricated, with programmed debonds of different geometries and sizes, to determine the sensitivity of shearography as a function of debond size, SOFI thickness,'and vacuum excitation. Results show that a Probability of Detection (POD) of 0.95 or better can be expected for debonds with a diameter equal to the SOFI thickness as less than 0.4-psi pressure reduction. More testing will be required to validate the laser shearography imaging process for certifying its use in nondestructive evaluation (NDE) of Space Shuttle space flight components.

Adams, F. W.↗
NASA NTRS2021

Thermal Inspection of a Composite Fuselage Section Using theMethod of Proper Generalized Decomposition

Proper Generalized Decomposition (PGD) is a reduced order modeling technique for the simulation of physical systems whose governing equations depend on boundary conditions, initial conditions, material properties, and geometric parameters. It uses separated representations of system covariates combined with an iterative approximation method known as successive enrichment in order to compute an accurate parameter-dependent approximation to the full governing equations. PGD can also be used as an alternative to the Singular Value Decomposition (SVD) of a matrix and therefore as an alternative to PCA thermography. In this paper PGD was used to analyze data derived from the inspection of a composite fuselage forward section using flash thermography, and the results were compared against the standard PCA approach.

Nondestructive Evaluation↗
NASA NTRS2014

Modeling the X-Ray Process, and X-Ray Flaw Size Parameter for POD Studies

Nondestructive evaluation (NDE) method reliability can be determined by a statistical flaw detection study called probability of detection (POD) study. In many instances the NDE flaw detectability is given as a flaw size such as crack length. The flaw is either a crack or behaving like a crack in terms of affecting the structural integrity of the material. An alternate approach is to use a more complex flaw size parameter. The X-ray flaw size parameter, given here, takes into account many setup and geometric factors. The flaw size parameter relates to X-ray image contrast and is intended to have a monotonic correlation with the POD. Some factors such as set-up parameters including X-ray energy, exposure, detector sensitivity, and material type that are not accounted for in the flaw size parameter may be accounted for in the technique calibration and controlled to meet certain quality requirements. The proposed flaw size parameter and the computer application described here give an alternate approach to conduct the POD studies. Results of the POD study can be applied to reliably detect small flaws through better assessment of effect of interaction between various geometric parameters on the flaw detectability. Moreover, a contrast simulation algorithm for a simple part-source-detector geometry using calibration data is also provided for the POD estimation.

Khoshti, Ajay↗
NASA NTRS2014

Modeling the X-ray Process, and X-ray Flaw Size Parameter for POD Studies

Nondestructive evaluation (NDE) method reliability can be determined by a statistical flaw detection study called probability of detection (POD) study. In many instances, the NDE flaw detectability is given as a flaw size such as crack length. The flaw is either a crack or behaving like a crack in terms of affecting the structural integrity of the material. An alternate approach is to use a more complex flaw size parameter. The X-ray flaw size parameter, given here, takes into account many setup and geometric factors. The flaw size parameter relates to X-ray image contrast and is intended to have a monotonic correlation with the POD. Some factors such as set-up parameters, including X-ray energy, exposure, detector sensitivity, and material type that are not accounted for in the flaw size parameter may be accounted for in the technique calibration and controlled to meet certain quality requirements. The proposed flaw size parameter and the computer application described here give an alternate approach to conduct the POD studies. Results of the POD study can be applied to reliably detect small flaws through better assessment of effect of interaction between various geometric parameters on the flaw detectability. Moreover, a contrast simulation algorithm for a simple part-source-detector geometry using calibration data is also provided for the POD estimation.

Koshti, Ajay M.↗
NASA NTRS2024

Considerations for Qualifying Reliable Eddy Current Array Technique for Detection of Backwall Cracks

A reliable nondestructive evaluation (NDE) technique provides minimum 90% probability of detection(POD) with 95% confidence for detection of cracklike flaws of a qualified size. In this case, the flaws are on backside of material. Eddy current array (ECA) probe or a single sensor eddy current probe in c-scanning mode is used for the flaw detection. Here, two geometries are considered for the test specimens. The two geometries are, a flat plate, and tube or pipe. The probe is assumed to be on outer diameter (OD)surface and the flaw is assumed to be at the inner diameter (ID) surface for tube inspection. The flaw and probe are on opposite side of wall thickness for inspection of plate material. The application may be used for acreage inspection or just for inspection of butt weld and heat affected zone (HAZ) in a tube, cylinder, or plate. The proposed approach is based on developing an instrument standardization or calibration procedure. Decision threshold of inspection procedure is determined using empirical qualification and noise data. The work explores essential parameters that are required to meet certain conditions to ensure reliable flaw detection. Physics-based simulation of eddy current array flaw detection is used to understand effect of essential parameters on signal response (amplitude and phase),and therefore flaw detectability. Simulation data is used to justify choice of calibration reference standard requirements and the qualification approach. An ECA technique qualification model is provided. The paper gives brief description of tasks to be completed for qualifying ECA technique for reliable detection of cracklike flaws.

Eddy current array inspection, nondestructive eval↗
NASA NTRSDate not supplied

Nondestructive Evaluation for the Space Shuttle's Wing Leading Edge

The loss of the Space Shuttle Columbia highlighted concerns about the integrity of the Shuttle's thermal protection system, which includes Reinforced Carbon-Carbon (RCC) on the leading edge. This led NASA to investigate nondestructive evaluation (NDE) methods for certifying the integrity of the Shuttle's wing leading edge. That investigation was performed simultaneously with a large study conducted to understand the impact damage caused by errant debris. Among the many advanced NDE methods investigated for applicability to the RCC material, advanced digital radiography, high resolution computed tomography, thermography, ultrasound, acoustic emission and eddy current systems have demonstrated the maturity and success for application to the Shuttle RCC panels. For the purposes of evaluating the RCC panels while they are installed on the orbiters, thermographic detection incorporating principal component analysis (PCA) and eddy current array scanning systems demonstrated the ability to measure the RCC panels from one side only and to detect several flaw types of concern. These systems were field tested at Kennedy Space Center (KSC) and at several locations where impact testing was being conducted. Another advanced method that NASA has been investigating is an automated acoustic based detection system. Such a system would be based in part on methods developed over the years for acoustic emission testing. Impact sensing has been demonstrated through numerous impact tests on both reinforced carbon-carbon (RCC) leading edge materials as well as Shuttle tile materials on representative aluminum wing structures. A variety of impact materials and conditions have been evaluated including foam, ice, and ablator materials at ascent velocities as well as simulated hypervelocity micrometeoroid and orbital debris impacts. These tests have successfully demonstrated the capability to detect and localize impact events on Shuttle's wing structures. A first generation impact sensing system has been designed for the next Shuttle flight and is undergoing final evaluation for deployment on the Shuttle's first return to flight. This system will employ wireless accelerometer sensors that were qualified for other applications on previous Shuttle flights. These sensors will be deployed on the wing's leading edge to detect impacts on the RCC leading edge panels. The application of these methods will help to insure the continued integrity of the Shuttle wing's leading edge system as the Shuttle flights resume and until their retirement.

Eric I Madaras↗