Search NASA⌕ Search

SEARCH · Search NASA

Results for “crack detection”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Propulsion Health Monitoring for Enhanced Safety

This report presents the results of the NASA contract Propulsion System Health Management for Enhanced Safety performed by General Electric Aircraft Engines (GE AE), General Electric Global Research (GE GR), and Pennsylvania State University Applied Research Laboratory (PSU ARL) under the NASA Aviation Safety Program. This activity supports the overall goal of enhanced civil aviation safety through a reduction in the occurrence of safety-significant propulsion system malfunctions. Specific objectives are to develop and demonstrate vibration diagnostics techniques for the on-line detection of turbine rotor disk cracks, and model-based fault tolerant control techniques for the prevention and mitigation of in-flight engine shutdown, surge/stall, and flameout events. The disk crack detection work was performed by GE GR which focused on a radial-mode vibration monitoring technique, and PSU ARL which focused on a torsional-mode vibration monitoring technique. GE AE performed the Model-Based Fault Tolerant Control work which focused on the development of analytical techniques for detecting, isolating, and accommodating gas-path faults.

Butz, Mark G.↗
NASA NTRS1979

Detection of hairline cracks in textured silicon solar cells

Using a focused laser scanner, the optical technique described in the present paper can be used to detect hairline cracks of the type occurring in solar cells subjected to surface texturing. The technique is capable of detecting cracks of the order of a few microns, which, otherwise, can be observed only under high magnification using an optical microscope. The technique consists of scanning a solar cell with a finely focused laser beam and recording the photoresponse (short circuit current or open circuit voltage) as a function of beam position. The presence of a crack is manifested by a sharp dip in the photoresponse.

Sopori, B. L.↗
NASA NTRS2014

Coupling Damage-Sensing Particles to the Digitial Twin Concept

The research presented herein is a first step toward integrating two emerging structural health management paradigms: digital twin and sensory materials. Digital twin is an emerging life management and certification paradigm whereby models and simulations consist of as-built vehicle state, as-experienced loads and environments, and other vehicle-specific history to enable high-fidelity modeling of individual aerospace vehicles throughout their service lives. The digital twin concept spans many disciplines, and an extensive study on the full domain is out of the scope of this study. Therefore, as it pertains to the digital twin, this research focused on one major concept: modeling specifically the as-manufactured geometry of a component and its microstructure (to the degree possible). The second aspect of this research was to develop the concept of sensory materials such that they can be employed within the digital twin framework. Sensory materials are shape-memory alloys that undergo an audible phase transformation while experiencing sufficient strain. Upon embedding sensory materials with a structural alloy, this audible transformation helps improve the reliability of crack detection especially at the early stages of crack growth. By combining these two early-stage technologies, an automated approach to evidence-based inspection and maintenance of aerospace vehicles is sought.

Hochhalter, Jacob↗
NASA NTRS2020

Composite Overwrapped Pressure Vessel (COPV) Damage Tolerance Life Analysis Methodology and Test Best Practices

The NASA Engineering and Safety Center (NESC) Deputy Director requested an independent assessment to develop data to understand the limitations of linear elastic fracture mechanics (LEFM) computational methods used to predict fatigue crack growth rate (da/dN) behavior of small detectable cracks in thin metal liners for composite overwrapped pressure vessels (COPVs). The NESC assessment team was also requested to demonstrate a test-based methodology for validating damage tolerance requirements for COPVs with elastically responding metal liners where LEFM methods are not appropriate. This report contains the outcome of the NESC assessment.

Composite Overwrapped Pressure Vessels; Linear Ela↗
NASA NTRS2020

Composite Overwrapped Pressure Vessel (COPV) Damage Tolerance Life Analysis Methodology and Test Best Practices: Appendices

The NASA Engineering and Safety Center (NESC) Deputy Director requested an independent assessment to develop data to understand the limitations of linear elastic fracture mechanics (LEFM) computational methods used to predict fatigue crack growth rate (da/dN) behavior of small detectable cracks in thin metal liners for composite overwrapped pressure vessels (COPVs). The NESC assessment team was also requested to demonstrate a test-based methodology for validating damage tolerance requirements for COPVs with elastically responding metal liners where LEFM methods are not appropriate. This document contains the appendices to the main report.

Composite Overwrapped Pressure Vessels; Linear Ela↗
NASA NTRS1937

Strength of Welded Aircraft Joints

This investigation is a continuation of work started in 1928 and described in NACA-TR-348 which shows that the insertion of gusset plates was the most satisfactory way of strengthening a joint. Additional tests of the present series show that joints of this type could be improved by cutting out the portion of the plate between the intersecting tubes. T and lattice joints in thin-walled tubing 1 1/2 by 0.020 inch have somewhat lower strengths than joints in tubing of greater wall thickness because of failure by local buckling. In welding the thin-walled tubing, the recently developed "carburizing flux" process was found to be the only method capable of producing joints free from cracks. The "magnetic powder" inspection was used to detect cracks in the joints and flaws in the tubing.

Brueggeman, W C↗
NASA NTRS1994

Detection of Fatigue Cracks at Rivets with Self-Nulling Probe

A new eddy current probe developed at NASA Langley Research Center has been used to detect small cracks at rivets in aircraft lap splices [1]. The device has earlier been used to detect isolated fatigue cracks with a minimum detectable flaw size of roughly 1/2 to 1/3 the diameter of the probe [2]. The present work shows that the detectable flaw size for cracks originating at rivets can be greatly improved upon from that of isolated flaws. The use of a rotating probe method combined with spatial filtering has been used to detect 0.18 cm EDM notches, as measured from the rivet shank, with a 1.27 cm diameter probe and to detect flaws buried under the rivet head, down to a length of 0.076 cm, using a 0.32 cm diameter probe. The Self-Nulling Electromagnetic Flaw Detector induces a high density eddy current ring in the sample under test. A ferromagnetic flux focusing lens is incorporated such that in the absence of any inhomogeneities in the material under test only a minimal magnetic field will reach the interior of the probe. A magnetometer (pickup coil) located in the center of the probe therefore registers a null voltage in the absence of material defects. When a fatigue crack or other discontinuity is present in the test article the path of the eddy currents in the material is changed. The magnetic field associated with these eddy currents then enter into the interior of the probe, producing a large output voltage across the pickup coil leads. Further

Wincheski, Buzz↗
NASA NTRS1996

High speed thin plate fatigue crack monitor

A device and method are provided which non-destructively detect crack length and crack geometry in thin metallic plates. A non-contacting vibration apparatus produces resonant vibrations without introducing extraneous noise. Resulting resonant vibration shifts in cracked plates are correlated to known crack length in plates with similar resonant vibration shifts. In addition, acoustic emissions of cracks at resonance frequencies are correlated to acoustic emissions from known crack geometries.

Wincheski, Buzz A.↗
NASA NTRS1975

Assessment of NDE reliability data

Twenty sets of relevant nondestructive test (NDT) reliability data were identified, collected, compiled, and categorized. A criterion for the selection of data for statistical analysis considerations was formulated, and a model to grade the quality and validity of the data sets was developed. Data input formats, which record the pertinent parameters of the defect/specimen and inspection procedures, were formulated for each NDE method. A comprehensive computer program was written and debugged to calculate the probability of flaw detection at several confidence limits by the binomial distribution. This program also selects the desired data sets for pooling and tests the statistical pooling criteria before calculating the composite detection reliability. An example of the calculated reliability of crack detection in bolt holes by an automatic eddy current method is presented.

Yee, B. G. W.↗
NASA NTRS2005

Implementing Recommendations of the Columbia Accident Investigation Board: Development of On-Orbit IR Thermography

One of NASA's Space Shuttle Return-to-Flight (RTF) efforts has been to develop thermography for the on-orbit inspection of the Reinforced Carbon Carbon (RCC) portion of the Orbiter Wing Leading Edge (WLE). This paper addresses the capability of thermography to detect cracks in RCC by using in-plane thermal gradients that naturally occur on-orbit. Crack damage, which can result from launch debris impact, is a detection challenge for other on-orbit sensors under consideration for RTF, such as the Intensified Television Camera and Laser Dynamic Range Imager. We studied various cracks in RCC, both natural and simulated, along with material characteristics, such as emissivity uniformity, in steady-state thermography. Severity of crack, such as those likely and unlikely to cause burn through were tested, both in-air and in-vacuum, and the goal of this procedure was to assure crew and vehicle safety during reentry by identification and quantification of a damage condition while on-orbit. Expected thermal conditions are presented in typical shuttle orbits, and the expected damage signatures for each scenario are presented. Finally, through statistical signal detection, our results show that even at very low in-plane thermal gradients, we are able to detect damage at or below the threshold for fatality in the most critical sections of the WLE, with a confidence exceeding 1 in 10,000 probability of false negative.

Ottens, Brian P.↗
NASA NTRS2005

Implementing Recommendations of the Columbia Accident Investigation Board - Development of on-Orbit RCC Thermography

One of NASA s Space Shuttle Return-to-Flight (RTF) efforts has been to develop thermography for the on-orbit inspection of the Reinforced Carbon Carbon (RCC) portion of the Orbiter Wing Leading Edge (WLE). This paper addresses the capability of thermography to detect cracks in RCC by using in-plane thermal gradients that naturally occur on-orbit. Crack damage, which can result from launch debris impact, is a detection challenge for other on-orbit sensors under consideration for RTF, such as the Intensified Television Camera and Laser Dynamic Range Imager. We studied various cracks in RCC, both natural and simulated, along with material characteristics, such as emissivity uniformity, in steady-state thermography. Severity of crack, such as those likely and unlikely to cause burn through were tested, both in-air and in-vacuum, and the goal of this procedure was to assure crew and vehicle safety during re-entry by identification and quantification of a damage condition while on-orbit. Expected thermal conditions are presented in typical shuttle orbits, and the expected damage signatures for each scenario are presented. Finally, through statistical signal detection, our results show that even at very low in-plane thermal gradients, we are able to detect damage at or below the threshold for fatality in the most critical sections of the WLE, with a confidence exceeding 1 in 10,000 probability of false negative.

Ottens, Brian↗
NASA NTRS1973

Sensitivity and comparison evaluation of Saturn 5 liquid penetrants

Results of a sensitivity and comparison evaluation performed on six liquid penetrants that were used on the Saturn 5 vehicle and other space hardware to detect surface discontinuities are described. The relationship between penetrant materials and crack definition capabilities, the optimum penetrant materials evaluation method, and the optimum measurement methods for crack dimensions were investigated. A unique method of precise developer thickness control was envolved, utilizing clear radiographic film and a densitometer. The method of evaluation included five aluminum alloy, 2219-T87, specimens that were heated and then quenched in cold water to produce cracks. The six penetrants were then applied, one at a time, and the crack indications were counted and recorded for each penetrant for comparison purposes. Measurements were made by determining the visual crack indications per linear inch and then sectioning the specimens for a metallographic count of the cracks present. This method provided a numerical approach for assigning a sensitivity index number to the penetrants. Of the six penetrants evaluated, two were not satisfactory (one was not sufficiently sensitive and the other was to sensitive, giving false indications). The other four were satisfactory with approximately the same sensitivity in the range of 78 to 80.5 percent of total cracks detected.

Jones, G. H.↗
NASA NTRS2002

Integrated Nondestructive Evaluation and Finite Element Analysis Predicts Crack Location and Shape

This study describes the finite-element analyses and the NDE modality undertaken on two flywheel rotors that were spun to burst speed. Computed tomography and dimensional measurements were used to nondestructively evaluate the rotors before and/or after they were spun to the first crack detection. Computed tomography data findings of two- and three-dimensional crack formation were used to conduct finite-element (FEA) and fracture mechanics analyses. A procedure to extend these analyses to estimate the life of these components is also outlined. NDE-FEA results for one of the rotors are presented in the figures. The stress results, which represent the radial stresses in the rim, clearly indicate that the maximum stress region is within the section defined by the computed tomography scan. Furthermore, the NDE data correlate well with the FEA results. In addition, the measurements reported show that the NDE and FEA data are in parallel.

Abdul-Azia, Ali↗
NASA NTRS2004

Methods and Piezoelectric Imbedded Sensors for Damage Detection in Composite Plates Under Ambient and Cryogenic Conditions

New methods for structural health monitoring are being assessed, especially in high-performance, extreme environment, safety-critical applications. One such application is for composite cryogenic fuel tanks. The work presented here attempts to characterize and investigate the feasibility of using imbedded piezoelectric sensors to detect cracks and delaminations under cryogenic and ambient conditions. A variety of damage detection methods and different Sensors are employed in the different composite plate samples to aid in determining an optimal algorithm, sensor placement strategy, and type of imbedded sensor to use. Variations of frequency, impedance measurements, and pulse echoing techniques of the sensors are employed and compared. Statistical and analytic techniques are then used to determine which method is most desirable for a specific type of damage. These results are furthermore compared with previous work using externally mounted sensors. Results and optimized methods from this work can then be incorporated into a larger composite structure to validate and assess its structural health. This could prove to be important in the development and qualification of any 2" generation reusable launch vehicle using composites as a structural element.

Engberg, Robert↗
NASA NTRS2003

Multi-Discipline Analytical Modeling of a Cracked Disk in a Turbine Engine: Applied to TF41 Experiment at China Lake

The investigated crack detection method is based on the fact that the development of a disk crack results in a distorted strain field within the component. As a result, a minute deformation in the disk's geometry as well as a change in the system's center of mass occurs. Finite element analyses were conducted concerning a notched disk in order to define the sensitivity of the method. The notch was used to simulate an actual crack and will be the method utilized for upcoming experiments. Various notch sizes were studied and the geometric deformations and shifts of center of mass were documented as a function of rotational speed. In addition, a rotordynamic analysis of a two-bearing, disk and shaft system was conducted. The results of the FE analyses of the disk indicated that the overall changes in the disk's geometry and center of mass were rather small. Comparing the 9.25 in. disk's maximum radial displacements due centrifugal forces at 8000 RPM between an un-notched and a 0.962 in. notched disk, the difference was on the order of 0.00014 in. The shift in center of mass was also of this magnitude. The next step involves running experiments to verify the analysis.

Sawicki, Jerzy T.↗
NASA NTRS2008

Effect of Liquid Penetrant Sensitivity on Probability of Detection

The objective of the task is to investigate the effect of liquid penetrant sensitivity level on probability of crack detection (POD). NASA-STD-5009 currently requires the use of only sensitivity level 4 liquid penetrants. This requirement is based on the fact that the data generated in the NTIAC Nondestructive Evaluation (NDE) Capabilities Data Book was produced using only sensitivity level 4 penetrants. Many NDE contractors supporting NASA Centers routinely use sensitivity level 3 penetrants. Because of the new NASA-STD-5009 requirement, these contractors will have to either shift to sensitivity level 4 penetrants or perform formal POD demonstration tests to qualify their existing process.

Parker, Bradford H.↗
NASA NTRS1978

Damage-detection system for LNG carriers

System utilizes array of acoustical transducers to detect cracks and leaks in liquefied natural gas (LNG) containers onboard ships. In addition to detecting leaks, device indicates location and leak rate.

Mastandrea, J. R.↗
NASA NTRS1991

An integrated eddy current detection and imaging system on a silicon chip

Eddy current probes have been used for many years for numerous sensing applications including crack detection in metals. However, these applications have traditionally used the eddy current effect in the form of a physically wound single or different probe pairs which of necessity must be made quite large compared to microelectronics dimensions. Also, the traditional wound probe can only take a point reading, although that point might include tens of individual cracks or crack arrays; thus, conventional eddy current probes are beset by two major problems: (1) no detailed information can be obtained about the crack or crack array; and (2) for applications such as quality assurance, a vast amount of time must be taken to scan a complete surface. Laboratory efforts have been made to fabricate linear arrays of single turn probes in a thick film format on a ceramic substrate as well as in a flexible cable format; however, such efforts inherently suffer from relatively large size requirements as well as sensitivity issues. Preliminary efforts to fully extend eddy current probing from a point or single dimensional level to a two dimensional micro-eddy current format on a silicon chip, which might overcome all of the above problems, are presented.

Henderson, H. Thurman↗