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A corona vacuum test facility for nondestructive testing of power system components was built in the Reliability and Quality Engineering Test Laboratories at the NASA Lewis Research Center. The facility was developed to simulate operating temperature and vacuum while monitoring corona discharges with residual gases. The facility is being used to test various high-voltage power system components.
A multifaceted program is described in which aeronautical, mechanical, and materials engineers interact to develop composite aircraft structures. Topics covered include: (1) the design of an advanced composite elevator and a proposed spar and rib assembly; (2) optimizing fiber orientation in the vicinity of heavily loaded joints; (3) failure mechanisms and delamination; (4) the construction of an ultralight sailplane; (5) computer-aided design; finite element analysis programs, preprocessor development, and array preprocessor for SPAR; (6) advanced analysis methods for composite structures; (7) ultrasonic nondestructive testing; (8) physical properties of epoxy resins and composites; (9) fatigue in composite materials, and (10) transverse thermal expansion of carbon/epoxy composites.
At Wright Patterson AFB, holographic interferometry has been used for nearly 15 years in a variety of supersonic and hypersonic wind tunnels. Specifically, holographic interferometry was used to study boundary layers, shock boundary layer interaction, and general flow diagnostics. Although a considerable amount of quantitative work was done, the difficulty of reducing data severely restricted this. In the future, it is of interest to use holographic interferometry in conjunction with laser Doppler velocimetry to do more complete diagnostics. Also, there is an interest to do particle field diagnostics in the combustion research facility. Finally, there are efforts in nondestructive testing where automated fringe readout and analysis would be extremely helpful.
An area that shows promise in enhancing structural integrity of aircraft and aerospace structures is the integrally stitched composite technology. The most recent generation of this technology is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept developed by Boeing Research and Technology and the National Aeronautics and Space Administration. A joint test program on the assessment of damage containment capabilities of the PRSEUS concept for curved fuselage structures was conducted recently at the Federal Aviation Administration William J. Hughes Technical Center. The panel was subjected to axial tension, internal pressure, and combined axial tension and internal pressure load conditions up to fracture, with a through-the-thickness, two-bay notch severing the central stiffener. For the purpose of future progressive failure analysis development and verification, extensive post failure nondestructive and teardown inspections were conducted. Detailed inspections were performed directly ahead of the notch tip where stable damage progression was observed. These examinations showed: 1) extensive delaminations developed ahead of the notch tip, 2) the extent and location of damage, 3) the typical damage mechanisms observed in composites, and 4) the role of stitching and warp-knitting in the failure mechanisms. The objective of this paper is to provide a summary of results from these posttest inspections.
The recently-completed NASA Advanced Composites Project (ACP) successfully developed several new technologies aimed at reducing the timeline to design and certify composite aircraft structures. Advancements in the areas of manufacturing simulation, nondestructive inspection and advanced structural design and analysis methodologies were completed in late 2019 under the Advanced Composites Consortium (ACC) public/private partnership as well as NRA-funded university contracts. In the area of Structures, the ACC made significant improvements in rapid design tools for preliminary sizing of structure, along with developing detailed static and fatigue strength prediction methods and methods for modeling high energy impact events in composite structures. These new methodologies and toolsets were validated against a range of representative test data using a comprehensive verification and validation approach which has been published and is now used extensively on other programs. Specific new tool improvements supported by ACC include NASA’s CompDam code and Floating Node Method code. CompDam is now available from NASA as open source code. The team alsoworked on improved impact modeling using LS-Dyna™ and improved delamination modeling using Abaqus™. Rapid design tool improvements are available through Hypersizer. The ACC team released well over 50 publications documenting these method improvements, and the ACP recently received the prestigious NASA Group Achievement Award for their work.Typical Hat Stiffened Panel Test Article Used for Method Validation
In this research, it is demonstrated that the integration of nondestructive evaluation with the finite element method (a quantitative NDE/FEM approach) can be used for analysis and behavior prediction of advanced materials, such as fiber composites, after processing and during in-service testing. First, stress, strain, and energy data were calculated by the finite element method for square plates with a 10 percent difference in the material properties between specified segments, i.e., between the center and the outside section or between two halves of the plate. This demonstrated the efficiency of the method in predicting variations in the structural behavior based on small material property differences. Then, finite element analyses and actual axial compression tests were performed on a Space Shuttle brake stator made from woven carbon-carbon composites. The material properties used in the numerical modeling of the stator were previously characterized at a large number of points on the component by quantitative NDE-procedures, i.e., ultrasonics and radiography. The results from the experimental compressive loading tests were used to verify the NDE/FEM results. Good agreement was found for most parameters.
The far-field displacements in an infinite transversely isotropic elastic medium subjected to an oscillatory concentrated force are derived. The concepts of velocity surface, slowness surface and wave surface are used to describe the geometry of the wave propagation process. It is shown that the decay of the wave amplitudes depends not only on the distance from the source (as in isotropic media) but also depends on the direction of the point of interest from the source. As an example, the displacement field is computed for a laboratory fabricated unidirectional fiberglass epoxy composite. The solution for the displacements is expressed as an amplitude distribution and is presented in polar diagrams. This analysis has potential usefulness in the acoustic emission (AE) and ultrasonic nondestructive evaluation of composite materials. For example, the transient localized disturbances which are generally associated with AE sources can be modeled via this analysis. In which case, knowledge of the displacement field which arrives at a receiving transducer allows inferences regarding the strength and orientation of the source, and consequently perhaps the degree of damage within the composite.
The fracture analysis conducted on four HPOTP (High Pressure Oxygen Turbopump) bearing balls from the SSME (Space Shuttle Main Engine) is described. Nondestructive evaluation, optical microscopy, and transmission microscopy techniques were used in the analysis. The cracks are initiated at or close to the ball surface under conditions of high cyclic stresses and high coefficient of friction. The cracks lead to spalls and subsequent crack propagation occurs by fatigue mode under concentrated loading of cyclic nature.
NASA White Sands Test Facility (WSTF) is leading an evaluation effort in advanced destructive and nondestructive testing of composite pressure vessels and structures. WSTF is using progressive finite element analysis methods for test design and for confirmation of composite pressure vessel performance. Using composite finite element analysis models and failure theories tested in the World-Wide Failure Exercise, WSTF is able to estimate the static strength of composite pressure vessels. Additionally, test and evaluation on composites that have been impact damaged is in progress so that models can be developed to estimate damage tolerance and the degradation in static strength.
Advanced material systems and designs require improved nondestructive evaluation (NDE) techniques for quality control, failure analysis and properties monitoring. Some advanced NDE techniques such as infrared scanning systems, laser holographic applications and the use of the Mossbauer effect are outlined. Applications of these techniques are discussed for evaluating the new space shuttle external insulation materials, aircraft structures and engine components, and precursors to crack initiation and growth.
The experimental and analytical efforts performed for fracture control of the Space Shuttle auxiliary power unit (APU) wheel are described and a summary of fracture mechanics concepts relevant to safe-life analysis of fatigue loaded parts is given. An environmental crack growth test program is conducted by NASA on candidate wheel materials exposed to decomposed hydrazine which is found to be no more severe in causing crack growth than an environment of high-temperature air. Details of the crack growth testing and the safe-life analysis are presented. The results show that special nondestructive examination is needed for the APU wheel to meet the required mission life for either the maximum design or expected speed-range operations.
Promising nondestructive-testing method based on ultrasonic simulation of stress waves. Report reviews acousto-ultrasonic technology for nondestructive testing. Discusses principles, suggests advanced signal-analysis schemes for development, and presents potential applications. Acousto-ultrasonics applied principally to assess defects in laminated and filament-wound fiber-reinforced composite materials. Technique used to determine variations in such properties as tensile, shear, and flexural strengths and reductions in strength and toughness caused by defects. Also used to evaluate states of cure, porosities, orientation of fibers, volume fractions of fibers, bonding between fibers and matrices, and qualities of interlaminar bonds.
Quantitative Nondestructive Evaluation (QNDE) is the technology of measurement, analysis, and prediction of the state of material/structural systems for safety, reliability, and mission assurance. QNDE has impact on everyday life from the cars we drive, the planes we fly, the buildings we work or live in, literally to the infrastructure of our world. Here, researchers highlight some of the new sciences and technologies that are part of a safer, cost effective tomorrow. Specific technologies that are discussed are thermal QNDE of aircraft structural integrity, ultrasonic QNDE for materials characterization, and technology spinoffs from aerospace to the medical sector. In each case, examples are given of how new requirements result in enabling measurement technologies, which in turn change the boundaries of design/practice.
The project involved detailed investigations into the failure mechanisms in composite plates as a function of hole size (holes centrally located in the plates) under static loading. There were two phases to the project, the first dealing with uniaxial loads along the fiber direction, and the second dealing with coplanar biaxial loading. Results for the uniaxial tests have been reported and published previously, thus this report will place emphasis on the second phase of the project, namely the biaxial tests. The composite plates used in the biaxial loading experiments, as well as the uniaxial, were composed of a single ply unidirectional graphite/epoxy prepreg sandwiched between two layers of transparent thermoplastic. This setup enabled us to examine the failure initiation and propagation modes nondestructively, during the test. Currently, similar tests and analysis of results are in progress for graphite/epoxy cruciform shaped flat laminates. The results obtained from these tests will be available at a later time.
The Cassini spacecraft mission to Saturn will be launched in October 1997, on a Titan IV/Centaur launch vehicle. Cassini is the largest interplanetary spacecraft ever developed. Before launch approval can be obtained, a test verified finite element model of the Cassini spacecraft must be completed and approved by NASA. The correctness of this model is critical to the final verification coupled loads analysis and margin of safety assessments.
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.
Fourier transform-infrared (FT-IR) spectroscopy has been used to rapidly and nondestructively analyze bacteria, bacteria-polymer mixtures, digester samples and microbial biofilms. Diffuse reflectance FT-IR (DRIFT) analysis of freeze-dried, powdered samples offered a means of obtaining structural information. The bacteria examined were divided into two groups. The first group was characterized by a dominant amide I band and the second group of organisms displayed an additional strong carbonyl stretch at approximately 1740 cm-1. The differences illustrated by the subtraction spectra obtained for microbes of the two groups suggest that FT-IR spectroscopy can be utilized to recognize differences in microbial community structure. Calculation of specific band ratios has enabled the composition of bacteria and extracellular or intracellular storage product polymer mixtures to be determined for bacteria-gum arabic (amide I/carbohydrate C-O approximately 1150 cm-1) and bacteria-poly-beta-hydroxybutyrate (amide I/carbonyl approximately 1740 cm-1). The key band ratios correlate with the compositions of the material and provide useful information for the application of FT-IR spectroscopy to environmental biofilm samples and for distinguishing bacteria grown under differing nutrient conditions. DRIFT spectra have been obtained for biofilms produced by Vibrio natriegens on stainless steel disks. Between 48 and 144 h, an increase in bands at approximately 1440 and 1090 cm-1 was seen in FT-IR spectra of the V. natriegens biofilm. DRIFT spectra of mixed culture effluents of anaerobic digesters show differences induced by shifts in input feedstocks. The use of flow-through attenuated total reflectance has permitted in situ real-time changes in biofilm formation to be monitored and provides a powerful tool for understanding the interactions within adherent microbial consortia.
The papers presented in this volume cover a variety of topics, including sound intensity, structural intensity, modal analysis and synthesis, statistical energy analysis and energy methods, passive and active damping, and boundary element methods. Attention is also given to diagnostics and condition monitoring, material characterization and nondestructive evaluation, active noise and vibration control, sound radiation and scattering, and finite element analysis.