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At least 109 records · Page 6

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NASA NTRS2003

Spiral Bevel Pinion Crack Detection in a Helicopter Gearbox

The vibration resulting from a cracked spiral bevel pinion was recorded and analyzed using existing Health and Usage Monitoring System (HUMS) techniques. A tooth on the input pinion to a Bell OH-58 main rotor gearbox was notched and run for an extended period at severe over-torque condition to facilitate a tooth fracture. Thirteen vibration-based diagnostic metrics were calculated throughout the run. After 101.41 hours of run time, some of the metrics indicated damage. At that point a visual inspection did not reveal any damage. The pinion was then run for another 12 minutes until a proximity probe indicated that a tooth had fractured. This paper discusses the damage detection effectiveness of the different metrics and a comparison of effects of the different accelerometer locations.

Decker, Harry J.↗

NASA NTRS2007

Replica-based Crack Inspection

A surface replica-based crack inspection method has recently been developed for use in Space Shuttle main engine (SSME) hydrogen feedline flowliners. These flowliners exist to ensure favorable flow of liquid hydrogen over gimble joint bellows, and consist of two rings each containing 38 elongated slots. In the summer of 2002, multiple cracks ranging from 0.1 inches to 0.6 inches long were discovered; each orbiter contained at least one cracked flowliner. These long cracks were repaired and eddy current inspections ensured that no cracks longer than 0.075 inches were present. However, subsequent fracture-mechanics review of flight rationale required detection of smaller cracks, and was the driving force for development of higher-resolution inspection method. Acetate tape surface replicas have been used for decades to detect and monitor small cracks. However, acetate tape replicas have primarily been limited to laboratory specimens because complexities involved in making these replicas - requiring acetate tape to be dissolved with acetone - are not well suited for a crack inspection tool. More recently developed silicon-based replicas are better suited for use as a crack detection tool. A commercially available silicon-based replica product has been determined to be acceptable for use in SSME hydrogen feedlines. A method has been developed using this product and a scanning electron microscope for analysis, which can find cracks as small as 0.005 inches and other features (e.g., pits, scratches, tool marks, etc.) as small as 0.001 inches. The resolution of this method has been validated with dozens of cracks generated in a laboratory setting and this method has been used to locate 55 cracks (ranging in size from 0.040 inches to 0.004 inches) on space flight hardware. These cracks were removed by polishing away the cracked material and a second round of replicas confirmed the repair.

Newman, John A.↗

NASA NTRS2010

Improving Bone-Health Monitoring in Astronauts: Recommended Use of Quantitative Computed Tomography [QCT] for Clinical and Operational Decisions by NASA

DXA measurement of areal bone mineral density [aBMD,g/cm2] is required by NASA for assessing skeletal integrity in astronauts. Due to the abundance of population-based data that correlate hip and spine BMDs to fragility fractures, BMD is widely applied as a predictor of fractures in the general aging population. In contrast, QCT is primarily a research technology that measures three-dimensional , volumetric BMD (vBMD,mg/cm3) of bone and is therefore capable of differentiating between cortical and trabecular components. Additionally, when combined with Finite Element Modeling [FEM], a computational tool, QCT data can be used to estimate the whole bone strength of the hip [FE strength] for a specific load vector. A recent report demonstrated that aBMD failed to correlate with incurred changes in FE strength (for fall and stance loading) by astronauts over typical 180-day ISS (International Space Station) missions. While there are no current guidelines for using QCT data in clinical practice, QCT increases the understanding of how bone structure and mineral content are affected by spaceflight and recovery on Earth. In order to understand/promote/consider the use of QCT, NASA convened a panel of clinicians specializing in osteoporosis. After reviewing the available, albeit limited, medical and research information from long-duration astronauts (e.g., data from DXA, QCT, FEM, biochemistry analyses, medical records and in-flight exercise performance) the panelists were charged with recommending how current and future research data and analyses could inform clinical and operational decisions. The Panel recommended that clinical bone tests on astronauts should include QCT (hip and lumbar spine) for occupational risk surveillance and for the estimation of whole hip bone strength as derived by FEM. FE strength will provide an improved index that NASA could use to select astronauts of optimal bone health for extended duration missions, for repeat missions or for specific mission operations.

Sibonga, J. D.↗

NASA NTRS2000

Intermediate Temperature Stress Rupture of Woven SiC Fiber, BN Interphase, SiC Matrix Composites in Air

Tensile stress-rupture experiments were performed on woven Hi-Nicalon reinforced SiC matrix composites with BN interphases in air. Modal acoustic emission (AE) was used to monitor the damage accumulation in the composites during the tests and microstructural analysis was performed to determine the amount of matrix cracking that occurred for each sample. Fiber fractograph), was also performed for individual fiber failures at the specimen fracture surface to determine the strengths at which fibers failed. The rupture strengths were significantly worse than what would have been expected front the inherent degradation of the fibers themselves when subjected to similar rupture conditions. At higher applied stresses the rate of rupture "?as larger than at lower applied stresses. It was observed that the change in rupture rate corresponded to the onset of through-thickness cracking in the composites themselves. The primary cause of the sen,ere degradation was the ease with which fibers would bond to one another at their closest separation distances, less than 100 nanometers, when exposed to the environment. The near fiber-to-fiber contact in the woven tows enabled premature fiber failure over large areas of matrix cracks due to the stress-concentrations created b), fibers bonded to one another after one or a few fibers fail. i.e. the loss of global load sharing. An@, improvement in fiber-to-fiber separation of this composite system should result in improved stress- rupture properties. A model was den,eloped in order to predict the rupture life-time for these composites based on the probabilistic nature of indin,idual fiber failure at temperature. the matrix cracking state during the rupture test, and the rate of oxidation into a matrix crack. Also incorporated into the model were estimates of the stress-concentration that would occur between the outer rim of fibers in a load-bearing bundle and the unbridged region of a matrix crack after Xia et al. For the lower stresses, this source of stress-concentration was the likely cause for initial fiber failure that would trigger catastrophic failure of the composite.

Morscher, Gregory N.↗

NASA NTRS2004

Development and Fatigue Testing of Ceramic Thermal Barrier Coatings

Ceramic thermal barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. Durability of the coating systems remains a critical issue with the ever-increasing temperature requirements. Thermal conductivity increase and coating degradation due to sintering and phase changes are known to be detrimental to coating performance. There is a need to characterize the coating thermal fatigue behavior and temperature limit, in order to potentially take full advantage of the current coating capability. In this study, thermal conductivity and cyclic fatigue behaviors of plasma-sprayed ZrO2-8wt%Y2O3 thermal barrier coatings were evaluated under high temperature, large thermal gradient and thermal cycling conditions. The coating degradation and failure processes were assessed by real-time monitoring of the coating thermal conductivity under the test conditions. The ceramic coating crack initiation and propagation driving forces and failure modes under the cyclic thermal loads will be discussed in light of the high temperature mechanical fatigue and fracture testing results.

Zhu, Dong-Ming↗

NASA NTRS1984

On the use of marker loads and replicas for measuring growth rates for small cracks

The initiation and growth of small cracks (5-500 microns) from edge notches in 2024-T3 aluminum alloy sheets were studied under constant-amplitude loading. Two methods were used to measure crack shape and size. In the first method, striation marker bands were periodically formed along the crack front by interrupting the constant-amplitude loading by either an elevated R-ratio load sequence, or by an overload sequence. In each case the marker loading was selected so as to have minimal influence on the growth rate under the primary loading. In the second method, the surface crack length was monitored by taking surface replicas at regular intervals. The marker band techniques did not provide reliable crack length and crack shape information for cracks smaller than 2 mm. The replica technique provided accurate information for surface crack length at all crack lengths, and fracture tests on specimens with small cracks provided crack-shape information.

Swain, M. H.↗

NASA NTRS1984

On the use of marker loads and replicas for measuring growth rates for small cracks

The initiation and growth of small cracks (5-500 microns m) from edge notches in 2024-T3 aluminum alloy sheets were studied under constant amplitude loading. Two methods were used to measure crack shape and size. In the first method, striation marker bands were periodically formed along the crack front by interrupting the constant amplitude loading by either an elevated R-ratio load sequence, or by an overload sequence. In the second method, the surface crack length was monitored by taking surface replicas at regular intervals. The marker band techniques did not provide reliable crack length and crack shape information for cracks smaller than 2 mm. The replica technique provided accurate information for surface crack length at all crack lengths, and fracture tests on specimens with small cracks provided crack-shape information. Crack growth rates were plotted against the stress intensity factor ranges. The results exhibited the small crack effect, in that the small cracks grew faster than large cracks at the same stress-intensity factor range. A crack closure model was also used to analyze the growth of small cracks from small (inclusion) defects at the notch surface.

Swain, M. H.↗

NASA NTRS1992

Fatigue damage in cross-ply titanium metal matrix composites containing center holes

The development of fatigue damage in (0/90) sub SCS-6/TI-15-3 laminates containing center holes was studied. Stress levels required for crack initiation in the matrix were predicted using an effective strain parameter and compared to experimental results. Damage progression was monitored at various stages of fatigue loading. In general, a saturated state of damage consisting of matrix cracks and fiber matrix debonding was obtained which reduced the composite modulus. Matrix cracks were bridged by the 0 deg fibers. The fatigue limit (stress causing catastrophic fracture of the laminates) was also determined. The static and post fatigue residual strengths were accurately predicted using a three dimensional elastic-plastic finite element analysis. The matrix damage that occurred during fatigue loading significantly reduced the notched strength.

Bakuckas, J. G., Jr.↗

NASA NTRS2005

Monitoring Eruptive Activity at Mount St. Helens with TIR Image Data

Thermal infrared (TIR) data from the MASTER airborne imaging spectrometer were acquired over Mount St. Helens in Sept and Oct, 2004, before and after the onset of recent eruptive activity. Pre-eruption data showed no measurable increase in surface temperatures before the first phreatic eruption on Oct 1. MASTER data acquired during the initial eruptive episode on Oct 14 showed maximum temperatures of similar to approximately 330 C and TIR data acquired concurrently from a Forward Looking Infrared (FLIR) camera showed maximum temperatures similar to approximately 675 C, in narrow (approximately 1-m) fractures of molten rock on a new resurgent dome. MASTER and FLIR thermal flux calculations indicated a radiative cooling rate of approximately 714 J/m(exp 2)/s over the new dome, corresponding to a radiant power of approximately 24 MW. MASTER data indicated the new dome was dacitic in composition, and digital elevation data derived from LIDAR acquired concurrently with MASTER showed that the dome growth correlated with the areas of elevated temperatures. Low SO2 concentrations in the plume combined with sub-optimal viewing conditions prohibited quantitative measurement of plume SO2. The results demonstrate that airborne TIR data can provide information on the temperature of both the surface and plume and the composition of new lava during eruptive episodes. Given sufficient resources, the airborne instrumentation could be deployed rapidly to a newly-awakening volcano and provide a means for remote volcano monitoring.

thermal emissions↗

NASA NTRS1988

Dynamic fracture toughness of ceramic composites

The dynamic fracture toughness vs crack velocity relationships of TiB2 particulate-reinforced SiC-matrix and SiC whisker-reinforced Al2O3-matrix composites were determined at both room temperature and 1200 C with impacted, single-edge notched three-point bend specimens. Rapid crack initiation and propagation were monitored by a laser interferometric-displacement gage system. A FEM model that transmitted the measured outside-impact load to the specimen within the furnace was used to characterize the entire loading system-specimen unit. Small differences were measured between the room temperature and 1200 C dynamic responses.

Yang, K. H.↗

NASA NTRS1996

Detecting Faults In Helicopter Gearboxes By The MVIM Method

Multivalued influence-matrix (MVIM) method potential utility as theoretical basis of proposed automated monitoring systems detecting faults in helicopter gearboxes. Applied to recognize patterns in vibration measurements. Fault-recognition system required to operate continuously while helicopter airborne, analyzing measurements of vibrations for signs of trouble to provide real-time warning of any dangerous or potentially dangerous fault like cracked case or fractured gear tooth. System also required not to give false alarms to prevent unnecessary emergency landings.

Chin, Hsinyung↗

NASA NTRS2005

Ultrasonic Guided-Wave-Scan System Used to Characterize C-Enhanced Silicon Carbide Composite During Creep- Rupture Tests

Ceramic matrix composites (CMCs) are being developed for advanced aerospace propulsion applications in order to save weight, improve reuse capability, and increase performance. However, mechanical and environmental loads applied to CMCs can cause degradation in the form of discrete flaws and distributed microdamage that can play a significant role in reducing desirable physical properties. Categories of microdamage include fiber/matrix debonding (interface failure), matrix microcracking, fiber fracture and buckling, oxidation, and second-phase formation. Distributed microdamage in CMCs has proven difficult to characterize nondestructively because of the complex microstructure and macrostructure of these materials, and a recent study regarding the durability of a ceramic matrix composite discussed the requirement for improved nondestructive evaluation (NDE) methods for monitoring degradation in these materials.

Roth, Don J.↗

NASA NTRS2016

Acoustic Emission of Large PRSEUS Structures (Pultruded Rod Stitched Efficient Unitized Structure)

In the role of structural health monitoring (SHM), Acoustic Emission (AE) analysis is being investigated as an effective method for tracking damage development in large composite structures under load. Structures made using Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) for damage tolerant, light, and economical airframe construction are being pursued by The Boeing Company and NASA under the Environmentally Responsible Aircraft initiative (ERA). The failure tests of two PRSEUS substructures based on the Boeing Hybrid Wing Body fuselage concept were conducted during third quarter 2011 and second quarter 2015. One fundamental concern of these tests was determining the effectiveness of the stitched integral stiffeners to inhibit damage progression. By design, severe degradation of load carrying capability should not occur prior to Design Ultimate Load (DUL). While minor damage prior to DUL was anticipated, the integral stitching should not fail since this would allow a stiffener-skin delamination to progress rapidly and alter the transfer of load into the stiffeners. In addition, the stiffeners should not fracture because they are fundamental to structural integrity. Getting the best information from each AE sensor is a primary consideration because a sparse network of sensors is implemented. Sensitivity to stiffener-contiguous degradation is supported by sensors near the stiffeners, which increases the coverage per sensor via AE waveguide actions. Some sensors are located near potentially critical areas or "critical zones" as identified by numerical analyses. The approach is compared with the damage progression monitored by other techniques (e.g. ultrasonic C-scan).

Horne, Michael R.↗

NASA NTRS1995

Transmission diagnostic research at NASA Lewis Research Center

The NASA Lewis Research Center and the U.S. Army Research Laboratory are involved in a joint research program to advance the technology of aerospace transmissions. Within the last six years, a transmission diagnostics research team was formed to address current and future technology barriers in transmission diagnostics. The diagnostics team conducted a survey to determine critical needs of the diagnostics community. Survey results indicated that experimental verification of gear and bearing fault detection methods and damage magnitude assessment were considered the two most critical research areas of a highly reliable health and usage monitoring system. A plan was implemented by the diagnostics team to address these key research areas, by in-house research and university grants. A variety of transmission fault detection methods were applied to experimentally obtained fatigue data. Failure modes of the fatigue tests include a variety of gear pitting failures, tooth wear, tooth fracture, and bearing spalling failures. Accomplishments to date include verification of several specific gear diagnostic methods, verification of a new pattern recognition method to determine failure, and development of a new method to model gear tooth damage. This paper presents the results of these accomplishments in transmission diagnostics research at NASA Lewis Research Center.

Zakrajsek, J. J.↗

NASA NTRS1985

Effects of strain rate on delamination fracture toughness of graphite/epoxy

The objective of this paper is to evaluate various experimental techniques and analysis methods for the characterization of interlaminar fracture toughness, and to determine the effects of strain rate on that property for a graphite/epoxy composite. Mode I interlaminar fracture was investigated by means of a double-cantilever beam (DCB) specimen for AS-4/3501-6 graphite/epoxy. Hinged tabs were used to insure unrestrained rotation at the free ends. Specimens were loaded at quasi-static deflection rates of up to 8.5 mm/s corresponding to crack extension rates of over 51 mm/s. Crack extension was monitored by means of strain gages mounted on the surface of the specimen, or a conductive-paint circuit attached to the edge of the DCB specimen. Continuous records were obtained of load, deflection, and crack extension for determination of the strain energy release rate. The latter was expressed as a power law of the crack extension velocity. Results indicate that the strain energy release rate increases with crack velocity by up to 28 percent for the range of rates considered.

Daniel, I. M.↗

NASA NTRS1987

Rate effects on delamiantion fracture toughness of a toughened graphite/epoxy

The objective of this study was to determine the effects of loading rate on interlaminar fracture toughness of T300/F-185 graphite/epoxy composite, having an elastomer-modified epoxy resin matrix. Mode I interlaminar fracture was investigated by means of uniform width and width-tapered double cantilever beam (DCB) specimens. Hinged tabs were used to insure unrestrained rotation at the free ends. Specimens were loaded at quasi-static deflection rates of up to 8.5 mm/s corresponding to crack extension rates of up to 21 mm/s. Crack extension was monitored by means of strain gages mounted on the surface of the specimen. Continuous records were obtained of load, deflection, and crack extension for determination of the strain energy release rate. The latter was calculated by means of the area method and beam analysis method, and expressed as a power law of the crack extension velocity. Results indicate that the strain energy release rate decreases with crack velocity by over 20 percent over three decades of crack velocity.

Daniel, Isaac M.↗

NASA NTRS1986

Airborne and spaceborne radar images for geologic and environmental mapping in the Amazon rain forest, Brazil

Spaceborne and airborne radar image of portions of the Middle and Upper Amazon basin in the state of Amazonas and the Territory of Roraima are compared for purposes of geological and environmental mapping. The contrasted illumination geometries and imaging parameters are related to terrain slope and surface roughness characteristics for corresponding areas that were covered by each of the radar imaging systems. Landforms range from deeply dissected mountain and plateau with relief up to 500 m in Roraima, revealing ancient layered rocks through folded residual mountains to deeply beveled pediplain in Amazonas. Geomorphic features provide distinct textural signatures that are characteristic of different rock associations. The principle drainages in the areas covered are the Rio Negro, Rio Branco, and the Rio Japura. Shadowing effects and low radar sensitivity to subtle linear fractures that are aligned parallel or nearly parallel to the direction of radar illumination illustrate the need to obtain multiple coverage with viewing directions about 90 degrees. Perception of standing water and alluvial forest in floodplains varies with incident angle and with season. Multitemporal data sets acquired over periods of years provide an ideal method of monitoring environmental changes.

Ford, John P.↗

NASA NTRS1973

Evaluate the application of ERTS-A data for detecting and mapping sea ice

The author has identified the following significant results. The results of the analysis of data collected during the spring and summer demonstrate that ERTS-1 imagery has a high potential for monitoring arctic sea ice conditions during the time for maximum ice extent through ice-breakup season. In the eastern Beaufort Sea area, the combination of ERTS-1 orbital overlap and a high incidence of cloud-free conditions during the spring assures a high frequency of repetitive satellite coverage. In the mid-Beaufort Sea, numerous fractures and leads can be identified, even in the early spring data. Ice features that can be identified include: development of fractures leading to the formation of distinct ice floes; growth and deterioration of leads; evidence of shearing movements of ice masses; formation of new grey ice within leads; distinction between grey, grey-white, and older forms of ice; and the deterioration of the ice surface evidenced by the formation of puddles, thaw holes, and drainage patterns. Ice conditions in the Bering Sea near St. Lawrence Island reported by aircraft observers participating in the Bering Sea Expedition are in close agreement with the ice conditions mapped from the corresponding ERTS-1 imagery. Ice features identified were: boundaries between grey ice and first year ice, shear leads, and occurrence of open water.

Barnes, J. C.↗