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At least 91 records · Page 5

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NASA NTRS1974

Space shuttle: Structural integrity and assessment study

A study program was conducted to determine the nondestructive evaluation (NDE) requirements and to develop a preliminary nondestructive evaluation manual for the entire space shuttle vehicle. The rationale and guidelines for structural analysis and NDE requirements development are discussed. Recommendations for development of NDE technology for the orbiter thermal protection system and certain structural components are included. Recommendations to accomplish additional goals toward space shuttle inspection are presented.

Pless, W. M.↗

NASA NTRS1998

Detection, Location, and Classification of Space Shuttle Main Engine Nozzle Leaks by Transient Thermographic Inspection

Leak checking and evaluation of pressure vessels by observing the slight temperature changes resulting from structural anomalies has been made possible through developments in high resolution infrared cameras and advanced image processing. These developments have made thermal nondestructive analysis a very practical and efficient method to determine material consistency and structural quality as well as monitor processes. The Space Shuttle Main Engine Nozzle has regions which can not be inspected with standard leak check methods. The Thermographic methods being developed to nondestructively test the Nozzle for leaks in inaccessible regions are reported. Also, a flash heating Thermographic investigation of the braze line bonding the cooling tubes to the outer structural jacket of the nozzle is reported.

Russell, Samuel S.↗

NASA NTRS1992

Advanced NDE research in electromagnetic, thermal, and coherent optics

A new inspection technology called magneto-optic/eddy current imaging was investigated. The magneto-optic imager makes readily visible irregularities and inconsistencies in airframe components. Other research observed in electromagnetics included (1) disbond detection via resonant modal analysis; (2) AC magnetic field frequency dependence of magnetoacoustic emission; and (3) multi-view magneto-optic imaging. Research observed in the thermal group included (1) thermographic detection and characterization of corrosion in aircraft aluminum; (2) a multipurpose infrared imaging system for thermoelastic stress detection; (3) thermal diffusivity imaging of stress induced damage in composites; and (4) detection and measurement of ice formation on the space shuttle main fuel tank. Research observed in the optics group included advancements in optical nondestructive evaluation (NDE).

Skinner, S. Ballou↗

NASA NTRS1982

Graphite/polyimide technology overview and Space Shuttle Orbiter applications

The materials, production processes, testing procedures, and repair techniques for composite structures on the Orbiter are reviewed. The Orbiter currently features graphite/epoxy payload bay doors, as well as graphite/polyimide elevons, vertical tail, and aft body flap, which can withstand up to 600 F temperatures. Graphite/polyimide is also being considered for areas of the baseline aluminum structure and the thermal protection system in order to achieve a 20-30% weight reduction, i.e., over 7.5 tons. An analysis of the allowable stresses on FRC imide thermal protection system tiles bonded directly to the structure has shown satisfactory performances in high temperature and cryogenic conditions, although failure modes are yet to be determined. Ultrasonic emissions have been used for defect detection in nondestructive evaluations, together with tension, notch, shear, and compression tests. Field repairs have not been perfected, and require the evolution of high temperature adhesives that are curable under vacuum pressure and heat blankets.

Morita, W. H.↗

NASA NTRS1992

Rapid detection and quantification of impact damage in composite structures

It is shown that a multidisciplinary nondestructive evaluation approach for impact damage detection in composite structures can be used to produce a more efficient inspection. The multidisciplinary NDE approach relies on fast large area thermographic inspections along with detailed ultrasonic volumetric imaging. The thermal inspection technique rapidly identifies the impact damage. The ultrasonic volumetric imaging quantifies the impact generated delaminations through the volume of the structure.

Smith, Barry T.↗

NASA NTRS1983

Engineering and fabrication cost considerations for cryogenic wind tunnel models

Design and fabrication cost drivers for cryogenic transonic wind tunnel models are defined. The major cost factors for wind tunnel models are model complexity, tolerances, surface finishes, materials, material validation, and model inspection. The cryogenic temperatures require the use of materials with relatively high fracture toughness but at the same time high strength. Some of these materials are very difficult to machine, requiring extensive machine hours which can add significantly to the manufacturing costs. Some additional engineering costs are incurred to certify the materials through mechanical tests and nondestructive evaluation techniques, which are not normally required with conventional models. When instrumentation such as accelerometers and electronically scanned pressure modules is required, temperature control of these devices needs to be incorporated into the design, which requires added effort. Additional thermal analyses and subsystem tests may be necessary, which also adds to the design costs. The largest driver to the design costs is potentially the additional static and dynamic analyses required to insure structural integrity of the model and support system.

Boykin, R. M., Jr.↗

NASA NTRS1993

Nondestructive analysis and development

This final report summarizes the achievements of project #4 of the NASA/UCF Cooperative Agreement from January 1990 to December 1992. The objectives of this project are to review NASA's NDE program at Kennedy Space Center (KSC) and recommend means for enhancing the present testing capabilities through the use of improved or new technologies. During the period of the project, extensive development of a reliable nondestructive, non-contact vibration technique to determine and quantify the bond condition of the thermal protection system (TPS) tiles of the Space Shuttle Orbiter was undertaken. Experimental modal analysis (EMA) is used as a non-destructive technique for the evaluation of Space Shuttle thermal protection system (TPS) tile bond integrity. Finite element (FE) models for tile systems were developed and were used to generate their vibration characteristics (i.e. natural frequencies and mode shapes). Various TPS tile assembly configurations as well as different bond conditions were analyzed. Results of finite element analyses demonstrated a drop in natural frequencies and a change in mode shapes which correlate with both size and location of disbond. Results of experimental testing of tile panels correlated with FE results and demonstrated the feasibility of EMA as a viable technique for tile bond verification. Finally, testing performed on the Space Shuttle Columbia using a laser doppler velocimeter demonstrated the application of EMA, when combined with FE modeling, as a non-contact, non-destructive bond evaluation technique.

Moslehy, Faissal A.↗

NASA NTRS1990

NASA airframe structural integrity program

NASA initiated a research program with the long-term objective of supporting the aerospace industry in addressing issues related to the aging of the commercial transport fleet. The program combines advanced fatigue crack growth prediction methodology with innovative nondestructive examination technology with the focus on multi-stage damage (MSD) at rivited connections. A fracture mechanics evaluation of the concept of pressure proof testing the fuselage to screen for MSD was completed. A successful laboratory demonstration of the ability of the thermal flux method to detect disbonds at rivited lap splice joints was conducted. All long-term program elements were initiated, and the plans for the methodology verification program are being coordinated with the airframe manufacturers.

Harris, Charles E.↗

NASA NTRS2001

Damage Assessment of Creep Tested and Thermally Aged Udimet 520 Using Acousto-Ultrasonics

Due to elevated temperatures and excessive stresses, turbine components may experience creep behavior. As a result, it is desirable to monitor and assess the current condition of such components. This study employed the Acousto-Ultrasonics (AU) method in an effort to monitor the state of the material at various percentages of used up creep life in the nickel base alloy, Udimet 520. A stepped specimen (i.e., varying cross sectional area) was employed which allowed for a postmortem nondestructive evaluation (NDE) analysis of the various levels of used up life. The overall objectives here were two fold: First, a user friendly, graphical interface AU system was developed, and second the new AU system was applied as an NDE tool to assess distributed damage resulting from creep. The experimental results demonstrated that the AU method shows promise as an NDE tool capable of detecting material changes as a function of used up creep life. Furthermore, the changes in the AU parameters were mainly attributed to the case of combined load and elevated temperature (i.e., creep) and not simply because of a timed exposure at elevated temperature (i.e., heat treatment or thermal aging).

Gyekenyesi, Andrew L.↗

NASA NTRS2008

Development and Characterization of the Bonding and Integration Technologies Needed for Fabricating Silicon Carbide Based Injector Components

Advanced ceramic bonding and integration technologies play a critical role in the fabrication and application of silicon carbide based components for a number of aerospace and ground based applications. One such application is a lean direct injector for a turbine engine to achieve low NOx emissions. Ceramic to ceramic diffusion bonding and ceramic to metal brazing technologies are being developed for this injector application. For the diffusion bonding technology, titanium interlayers (coatings and foils) were used to aid in the joining of silicon carbide (SiC) substrates. The influence of such variables as surface finish, interlayer thickness, and processing time were investigated. Electron microprobe analysis was used to identify the reaction formed phases. In the diffusion bonds, an intermediate phase, Ti5Si3Cx, formed that is thermally incompatible in its thermal expansion and caused thermal stresses and cracking during the processing cool-down. Thinner interlayers of pure titanium and/or longer processing times resulted in an optimized microstructure. Tensile tests on the joined materials resulted in strengths of 13-28 MPa depending on the SiC substrate material. Nondestructive evaluation using ultrasonic immersion showed well formed bonds. For the joining technology of brazing Kovar fuel tubes to silicon carbide, preliminary development of the joining approach has begun. Various technical issues and requirements for the injector application are addressed.

Halbig,Michael C.↗

NASA NTRS1991

NASA airframe structural integrity program

NASA has initiated a research program with the long-term objective of supporting the aerospace industry in addressing issues related to the aging commercial transport fleet. The interdisciplinary program combines advanced fatigue crack growth prediction methodology with innovative nondestructive examination technology with the focus on multi-site damage (MSD) at riveted connections. A fracture mechanics evaluation of the concept of pressure proof testing the fuselage to screen for MSD has been completed. Also, a successful laboratory demonstration of the ability of the thermal flux method to detect disbonds at riveted lap splice joints has been conducted. All long-term program elements have been initiated and the plans for the methodology verification program are being coordinated with the airframe manufacturers.

Harris, Charles E.↗

NASA NTRS1997

Application of Laser Based Ultrasound for NDE of Damage in Thick Stitched Composites

As design engineers implement new composite systems such as thick, load bearing composite structures, they must have certifiable confidence in structure s durability and worthiness. This confidence builds from understanding the structural response and failure characteristics of simple components loaded in testing machines to tests on full scale sections. Nondestructive evaluation is an important element which can provide quantitative information on the damage initiation, propagation, and final failure modes for the composite structural components. Although ultrasound is generally accepted as a test method, the use of conventional ultrasound for in-situ monitoring of damage during tests of large structures is not practical. The use of lasers to both generate and detect ultrasound extends the application of ultrasound to in- situ sensing of damage in a deformed structure remotely and in a non-contact manner. The goal of the present research is to utilize this technology to monitor damage progression during testing. The present paper describes the application of laser based ultrasound to quantify damage in thick stitched composite structural elements to demonstrate the method. This method involves using a Q-switched laser to generate a rapid, local linear thermal strain on the surface of the structure. This local strain causes the generation of ultrasonic waves into the material. A second laser used with a Fabry-Perot interferometer detects the surface deflections. The use of fiber optics provides for eye safety and a convenient method of delivering the laser over long distances to the specimens. The material for these structural elements is composed of several stacks of composite material assembled together by stitching through the laminate thickness that ranging from 0.5 to 0.8 inches. The specimens used for these nondestructive evaluation studies had either impact damage or skin/stiffener interlaminar failure. Although little or no visible surface damage existed, internal damage was detected by laser based ultrasound.

Anastasi, Robert F.↗

NASA NTRS1996

Stress Measurement System

Under the Aircraft Structural Integrity program, Langley Research Center and Stress Photonics developed an infrared-based stress measurement system for use in nondestructive evaluation of materials and structures. Stress Photonics commercialized the technology in the DeltaTherm 1000 system, used to compare designs and detect cracks in structures, especially for aging aircraft and bridges. The system combines digital signal processing technology with a special infrared camera to provide instantaneous thermal images and live differential images.

Source record↗

NASA NTRS2000

Thermographic Nondestructive Evaluation of the Space Shuttle Main Engine Nozzle

The methods and results presented in this summary address the thermographic identification of interstitial leaks in the Space Shuttle Main Engine nozzles. A highly sensitive digital infrared camera is used to record the minute cooling effects associated with a leak source, such as a crack or pinhole, hidden within the nozzle wall by observing the inner "hot wall" surface as the nozzle is pressurized. These images are enhanced by digitally subtracting a thermal reference image taken before pressurization, greatly diminishing background noise. The method provides a nonintrusive way of localizing the tube that is leaking and the exact leak source position to within a very small axial distance. Many of the factors that influence the inspectability of the nozzle are addressed; including pressure rate, peak pressure, gas type, ambient temperature and surface preparation.

Walker, James L.↗

NASA NTRSDate not supplied

Simulation of Thermographic Responses of Delaminations in Composites with Quadrupole Method

Thermography has been shown to be a viable technique for inspection of composites. The quadrupole method is a valuable technique for rapidly simulating the thermal response of layered systems. Often, the effort has focused on a one-dimensional model, in particular for improved analysis of thermal data. For composites, the in-plane heat diffusion often significantly impacts the thermal response of defects of interest, therefore three-dimensional simulations are desirable. This paper discusses the extension of the quadrupole methodology to perform simulations of thermographic responses in three-dimensional configurations. This enables the more realistic simulations of the thermal response of delaminations in composites. The simulations are compared to finite element simulations of the same inspection configurations.

Thermography↗

NASA NTRS1999

NDE Process Development Specification for SRB Composite Nose Cap

The Shuttle Upgrade program is a continuing improvement process to enable the Space Shuttle to be an effective space transportation vehicle for the next few decades. The Solid Rocket Booster (SRB), as a component of that system, is currently undergoing such an improvement. Advanced materials, such as composites, have given us a chance to improve performance and to reduce weight. The SRB Composite Nose Cap (CNC) program aims to replace the current aluminum nose cap, which is coated with a Thermal Protection System and poses a possible debris hazard, with a lighter, stronger, CNC. For the next 2 years, this program will evaluate the design, material selection, properties, and verification of the CNC. This particular process specification cites the methods and techniques for verifying the integrity of such a nose cap with nondestructive evaluation.

Suits, M.↗

NASA NTRS2001

Silicon Nitride Plates for Turbine Blade Application: FEA and NDE Assessment

Engine manufacturers are continually attempting to improve the performance and the overall efficiency of internal combustion engines. The thermal efficiency is typically improved by raising the operating temperature of essential engine components in the combustion area. This reduces the heat loss to a cooling system and allows a greater portion of the heat to be used for propulsion. Further improvements can be achieved by diverting part of the air from the compressor, which would have been used in the combustor for combustion purposes, into the turbine components. Such a process is called active cooling. Increasing the operating temperature, decreasing the cooling air, or both can improve the efficiency of the engine. Furthermore, lightweight, strong, tough hightemperature materials are required to complement efficiency improvement for nextgeneration gas turbine engines that can operate with minimum cooling. Because of their low-density, high-temperature strength, and thermal conductivity, ceramics are being investigated as potential materials for replacing ordinary metals that are currently used for engine hot section components. Ceramic structures can withstand higher operating temperatures and other harsh environmental factors. In addition, their low densities relative to metals helps condense component mass (ref. 1). The objectives of this program at the NASA Glenn Research Center are to develop manufacturing technology, a thermal barrier coating/environmental barrier coating (TBC/EBC), and an analytical modeling capability to predict thermomechanical stresses, and to do minimal burner rig tests of silicon nitride (Si3N4) and SiC/SiC turbine nozzle vanes under simulated engine conditions. Furthermore, and in support of the latter objectives, an optimization exercise using finite element analysis and nondestructive evaluation (NDE) was carried out to characterize and evaluate silicon nitride plates with cooling channels.

Abdul-Aziz, Ali↗

NASA NTRS2011

Material Characterization and Geometric Segmentation of a Composite Structure Using Microfocus X-Ray Computed Tomography Image-Based Finite Element Modeling

This study utilizes microfocus x-ray computed tomography (CT) slice sets to model and characterize the damage locations and sizes in thermal protection system materials that underwent impact testing. ScanIP/FE software is used to visualize and process the slice sets, followed by mesh generation on the segmented volumetric rendering. Then, the local stress fields around several of the damaged regions are calculated for realistic mission profiles that subject the sample to extreme temperature and other severe environmental conditions. The resulting stress fields are used to quantify damage severity and make an assessment as to whether damage that did not penetrate to the base material can still result in catastrophic failure of the structure. It is expected that this study will demonstrate that finite element modeling based on an accurate three-dimensional rendered model from a series of CT slices is an essential tool to quantify the internal macroscopic defects and damage of a complex system made out of thermal protection material. Results obtained showing details of segmented images; three-dimensional volume-rendered models, finite element meshes generated, and the resulting thermomechanical stress state due to impact loading for the material are presented and discussed. Further, this study is conducted to exhibit certain high-caliber capabilities that the nondestructive evaluation (NDE) group at NASA Glenn Research Center can offer to assist in assessing the structural durability of such highly specialized materials so improvements in their performance and capacities to handle harsh operating conditions can be made.

Abdul-Aziz, Ali↗