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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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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Reducing Aviation Fuel Costs with Non-Destructive Testing

Thermal barrier coatings (TBCs) are absolutely critical to the efficient and safe operation of gas turbine engines (GTEs). Manufacturing TBCs is a complex chemical, thermal and mechanical process that requires precise control. And yet, the variation in life of a TBC operated within a GTE is large. This variation ultimately reduces operational performance via a designed reduction to the turbine entry temperature, T4.This paper makes the case for developing advanced THz and sub-millimeter based nondestructive testing (NDT) techniques, capable of estimating when TBC components will fail. Such a technique could identify TBCs with low expected remaining useful lifetimes, directly after production. These TBCs could be re-manufactured, thereby not only improving their own expected useful life, but also the mean lifetime of the entire manufacturing population. A series of calculations demonstrates that TBCs with enhanced life characteristics can withstand higher T4 temperatures. Assuming that a GTE is to operate at a constant thrust, this increased temperature can be traded for a reduction in fuel flow. An analysis comparing fuel savings to manufacturing costs shows that substantial savings are achievable.

microwaves↗
NASA NTRS2020

Microwave Photoelasticity: A Resonant Wavelength Approach Applied to PEEK Polymer

Every nondestructive testing (NDT) technique has its unique set of advantages and limitations. Currently, the only existing noncontact NDT method capable of measuring sub-surface stresses, in optically opaque materials, at near-real-time speeds and over large areas is Microwave Photoelasticity (MP). This paper presents a new MP approach, which correlates changes in resonant wavelengths to changes in stress. In addition to a theoretical outline of the approach, the design and operation of an instrument capable of conducting these measurements is described. Finally, the technique is demonstrated by conducting measurements on polyetheretherketone, commonly known as PEEK, polymer. Between the W-Band frequencies of 105 to 115 GHz, PEEK’s stress-optic-coefficient was determined to be of 𝐶𝐶 = −0.20 ± 0.02 1/GPa.

Schemmel, Peter J.↗
NASA NTRS1976

Analytical study of acousto/optical holography-interfacing methods for acoustical and optical holography NDT research

The international status of the art of acousto optical imaging techniques adaptable to nondestructive testing and, interfacing methods for acoustical and optical holography in nondestructive testing research are studied. Evaluation of 20 different techniques encompassed investigation of varieties of detectors and detection schemes, all of which are described and summarized. Related investigation is reported in an Appendix. Important remarks on image quality, factors to be considered in designing a particular system, and conclusions and recommendations are presented. Three bibliographies are included.

El-Sum, H. M. A.↗
NASA NTRS1986

Buckling characteristics of hypersonic aircraft wing tubular panels

The buckling characteristics of Rene 41 tubular panels installed as wing panels on a hypersonic wing test structure (HWTS) were determined nondestructively through use of a force/stiffness technique. The nondestructive buckling tests were carried out under different combined load conditions and different temperature environments. Two panels were subsequently tested to buckling failure in a universal tension compression testing machine. In spite of some data scattering because of large extrapolations of data points resulting from termination of the test at a somewhat low applied load, the overall test data correlated fairly well with theoretically predicted buckling interaction curves. The structural efficiency of the tubular panels was slightly higher than that of the beaded panels which they replaced.

Ko, William L.↗
NASA NTRS1971

Radioactive nondestructive test method

Various radioisotope techniques were used as diagnostic tools for determining the performance of spacecraft propulsion feed system elements. Applications were studied in four tasks. The first two required experimental testing involving the propellant liquid oxygen difluoride (OF2): the neutron activation analysis of dissolved or suspended metals, and the use of radioactive tracers to evaluate the probability of constrictions in passive components (orifices and filters) becoming clogged by matter dissolved or suspended in the OF2. The other tasks were an appraisal of the applicability of radioisotope techniques to problems arising from the exposure of components to liquid/gas combinations, and an assessment of the applicability of the techniques to other propellants.

Obrien, J. R.↗
NASA NTRS1976

Exploratory loading techniques

Interferometric holographic nondestructive testing of aluminum, copper, and steel flat plates is reported. Structural weaknesses under positive pressure, negative pressure, heating, and cooling are discussed.

Martin, A. M., III↗
NASA NTRS1978

Dual hologram design study

A phase modulated triple exposure technique was incorporated into a holographic nondestructive test (HNDT) system. The technique was able to achieve a goal of simultaneously identifying the zero-order fringe and determining the direction of motion (or displacement). Basically, the technique involves the addition of one more exposure, during the loading of the tested object, to the conventional double-exposure hologram. A phase shifter is added to either the object beam or the reference beam during the second and third exposure. Theoretical analysis with the assistance of computer simulation illustrated the feasibility of implementing the phase modulation and triple-exposure in the HNDT systems. Main advantages of the technique are the enhancement of accuracy in data interpretation and a better determination of the nature of the flaws in the tested object.

Liu, H. K.↗
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 NTRS1974

Composite materials inspection

Investigation of the application requirements, advantages, and limitations of nondestructive testing by a technique of ultrasonic-vibration holographic-interferometry readout used in a production control facility for the inspection of a single product such as composite compressor blades. It is shown that, for the detection and characterization of disbonds in composite material structures, this technique may represent the most inclusive test method.

Erf, R. K.↗
NASA NTRS1984

Forecasting of high voltage insulation performance: Testing of recommended potting materials and of capacitors

Nondestructive high voltage test techniques (mostly electrical methods) are studied to prevent total or catastrophic breakdown of insulation systems under applied high voltage in space. Emphasis is on the phenomenon of partial breakdown or partial discharge (P.D.) as a symptom of insulation quality, notably partial discharge testing under D.C. applied voltage. Many of the electronic parts and high voltage instruments in space experience D.C. applied stress in service, and application of A.C. voltage to any portion thereof would be prohibited. Suggestions include: investigation of the ramp test method for D.C. partial discharge measurements; testing of actual flight-type insulation specimen; perfect plotting resin samples with controlled defects for test; several types of plotting resins and recommendations of the better ones from the electrical characteristics; thermal and elastic properties are also considered; testing of commercial capaciters; and approximate acceptance/rejection/rerating criteria for sample test elements for space use, based on D.C. partial discharge.

Bever, R. S.↗
NASA NTRS2020

Breakthrough Materials for Space Applications Workshop

In the course of its 60 year history, the National Aeronautics and Space Administration (NASA) has blazed trails in the development and advancement of aerospace materials and the transition of these advancements to industry. The Agency has overseen the infusion of new high-performance materials into a diverse array of mission applications, including aeronautics, planetary science, and human spaceflight. The next generation of demanding exploration missions, including a return to the lunar surface with humans in the 2020s, will present new and unprecedented material challenges. Selecting or developing materials to survive the environments of launch and the high temperatures present in propulsion systems, operate in a microgravity and/or a vacuum environment (which includes exposure to radiation), and/or survive years on a planetary surface is an immense challenge. In addition to functioning in their intended use environment, materials for space must also possess extremely high-performance characteristics. The anecdotal Von Braun quote “space is weightlifting” reminds us of the need to minimize the mass of a space system while still meeting safety margins. The cost of launching a kg to orbit is estimated currently at $10,000; barring a drastic reduction in launch costs, lightweight and high-strength materials will remain the most sought-after spaceflight materials for the foreseeable future. Other primary considerations for materials in spaceflight applications include affordability, compatibility with other systems and materials, and manufacturability. The emergence of new advanced manufacturing processes such as friction stir welding and additive manufacturing have revolutionized the aerospace industry in recent years. Additive manufacturing in particular allows for rapid fabrication of components and greater design freedom. With the advent of these new processes, however, comes the need to develop new specifications, process control approaches (including material modeling), testing, and nondestructive evaluation techniques to ensure that parts meet the stringent functional requirements for spaceflight.

Prater, T.↗
NASA NTRSDate not supplied

An Electron Backscatter Diffraction (EBSD)-Based Automated Tool for Ceramic Capacitor Grain Size Analysis

Ceramic capacitors continue to be recurring problem parts for NASA, despite best efforts to screen out potential defects and failures through environmental and electrical testing and nondestructive inspection techniques such as acoustic microscopy. The physical properties of ceramic capacitors necessitates thin dielectric layers capable of withstanding significant electric fields. Any defects in those ceramic layers can result in reduced insulation resistance failure modes including short circuit failures, so the quality and consistency of the dielectric material is critical. The size of the individual ceramic grains in the dielectric material is a critical parameter. However, judging “grain size” is not so simple—in a single capacitor there can be wide variation in grain sizes observed. It is theorized that by studying the grain size distributions of “known good” and “known bad” lots of capacitors, some conclusions could be drawn that would allow us to better predict to the reliability of future lots based on grain size distributions. The initial goal of this effort was to find or develop an automated tool that could inspect a capacitor and return grain size distribution results.

Robert Hodson↗
NASA NTRS1980

Triple-exposure holography for materials tests

Theoretical analysis of technique of triple exposure of holographic nondestructive testing shows that significant information can be extracted improving analysis of fringe pattern.

Liu, H. K.↗
NASA NTRS2010

Implications of Microwave Holography Using Minimum Required Frequency Samples for Weakly- and Strongly-Scattering Indications

Microwave imaging techniques, an integral component of nondestructive testing and evaluation (NDTE), have received significant attention in the past decade. These techniques have included the implementation of synthetic aperture focusing (SAF) algorithms for obtaining high spatial resolution images. The next important step in these developments is the implementation of 3-D holographic imaging algorithms. These are well-known wideband imaging technique requiring a swept-frequency (i.e., wideband), which unlike SAF that is a single frequency technique, are not easily performed on a real-time basis. This is due to the fact that a significant number of data points (in the frequency domain) must be obtained within the frequency band of interest. This not only makes for a complex imaging system design, it also significantly increases the image-production time. Consequently in an attempt to reduce the measurement time and system complexity, an investigation was conducted to determine the minimum required number of frequency samples needed to image a specific object while preserving a desired maximum measurement range and range resolution. To this end the 3-D holographic algorithm was modified to use properlyinterpolated frequency data. Measurements of the complex reflection coefficient for several samples were conducted using a swept-frequency approach. Subsequently, holographical images were generated using data containing a relatively large number of frequency samples and were compared with images generated by the reduced data set data. Quantitative metrics such as average, contrast, and signal-to-noise ratio were used to evaluate the quality of images generated using reduced data sets. Furthermore, this approach was applied to both weakly- and strongly-scattering indications. This paper presents the methods used and the results of this investigation.

Fallahpour, M.↗
NASA NTRS1983

Multiwavelength analyzer for the determination of diffusion lengths

The minority carrier diffusion length Ln in the base or substrate region is an important parameter which governs a solar cell's performance. The present investigation is concerned with the development of a multiwavelength analyzer (MWA) technique for the nondestructive spatial testing of polycrystalline solar cells. The MWA method is based on the utilization of the short-circuit current generated by two or more light-emitting diodes (LEDs) operating at different wavelengths and modulated 180 deg out-of-phase. For a determination of Ln by the MWA technique, it is necessary to know the value of the absorption coefficient.

Stafsudd, O. M.↗
NASA NTRS2005

Microwave and Millimeter Wave Imaging Using Synthetic Aperture Focusing and Holographical Techniques

Microwave and millimeter wave nondestructive testing and evaluation (NDT&E) methods have shown great potential for determining material composition in composite structures, determining material thickness or debond thickness between two layers, and determining the location and size of flaws, defects, and anomalies. The same testing methods have also shown great potential to produce relatively high-resolution images of voids inside Spray On Foam Insulation (SOFI) test panels using real focused methods employing lens antennas. An alternative to real focusing methods are synthetic focusing methods. The essence of synthetic focusing is to match the phase of the scattered signal to measured points spaced regularly on a plane. Many variations of synthetic focusing methods have already been developed for radars, ultrasonic testing applications, and microwave concealed weapon detection. Two synthetic focusing methods were investigated; namely, a) frequency-domain synthetic aperture focusing technique (FDSAFT), and b) wide-band microwave holography. These methods were applied towards materials whose defects were of low dielectric contrast like air void in SOFI. It is important to note that this investigation used relatively low frequencies from 8.2 GHz to 26.5 GHz that are not conducive for direct imaging of the SOFI. The ultimate goal of this work has been to demonstrate the capability of these methods before they are applied to much higher frequencies such as the millimeter wave frequency spectrum (e.g., 30-300 GHz).

Case, Joseph Tobias↗