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At least 109 records · Page 6

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NASA NTRS2005

Nondestructive Evaluation of Advanced Materials with X-ray Phase Mapping

X-ray radiation has been widely used for imaging applications since Rontgen first discovered X-rays over a century ago. Its large penetration depth makes it ideal for the nondestructive visualization of the internal structure and/or defects of materials unobtainable otherwise. Currently used nondestructive evaluation (NDE) tools, X-ray radiography and tomography, are absorption-based, and work well in heavy-element materials where density or composition variations due to internal structure or defects are high enough to produce appreciable absorption contrast. However, in many cases where materials are light-weight and/or composites that have similar mass absorption coefficients, the conventional absorption-based X-ray methods for NDE become less useful. Indeed, the light-weight and ultra-high-strength requirements for the most advanced materials used or developed for current flight mission and future space exploration pose a great challenge to the standard NDE tools in that the absorption contrast arising from the internal structure of these materials is often too weak to be resolved. In this presentation, a solution to the problem, the use of phase information of X-rays for phase contrast X-ray imaging, will be discussed, along with a comparison between the absorption-based and phase-contrast imaging methods. Latest results on phase contrast X-ray imaging of lightweight Space Shuttle foam in 2D and 3D will be presented, demonstrating new opportunities to solve the challenging issues encountered in advanced materials development and processing.

Hu, Zhengwei↗

NASA NTRS1979

A review of issues and strategies in nondestructive evaluation of fiber reinforced structural composites

Techniques for quantitative assessment of the mechanical strength and integrity of fiber composites during manufacture and service and following repair operations are presented. Problems and approaches are discussed relative to acceptance criteria, calibrating standards, and methods for nondestructive evaluation of composites in strength-critical applications. Acousto-ultrasonic techniques provide the methods of choice in this area.

Vary, A.↗

NASA NTRSDate not supplied

Nondestructive Evaluation for the Space Shuttle's Wing Leading Edge

The loss of the Space Shuttle Columbia highlighted concerns about the integrity of the Shuttle's thermal protection system, which includes Reinforced Carbon-Carbon (RCC) on the leading edge. This led NASA to investigate nondestructive evaluation (NDE) methods for certifying the integrity of the Shuttle's wing leading edge. That investigation was performed simultaneously with a large study conducted to understand the impact damage caused by errant debris. Among the many advanced NDE methods investigated for applicability to the RCC material, advanced digital radiography, high resolution computed tomography, thermography, ultrasound, acoustic emission and eddy current systems have demonstrated the maturity and success for application to the Shuttle RCC panels. For the purposes of evaluating the RCC panels while they are installed on the orbiters, thermographic detection incorporating principal component analysis (PCA) and eddy current array scanning systems demonstrated the ability to measure the RCC panels from one side only and to detect several flaw types of concern. These systems were field tested at Kennedy Space Center (KSC) and at several locations where impact testing was being conducted. Another advanced method that NASA has been investigating is an automated acoustic based detection system. Such a system would be based in part on methods developed over the years for acoustic emission testing. Impact sensing has been demonstrated through numerous impact tests on both reinforced carbon-carbon (RCC) leading edge materials as well as Shuttle tile materials on representative aluminum wing structures. A variety of impact materials and conditions have been evaluated including foam, ice, and ablator materials at ascent velocities as well as simulated hypervelocity micrometeoroid and orbital debris impacts. These tests have successfully demonstrated the capability to detect and localize impact events on Shuttle's wing structures. A first generation impact sensing system has been designed for the next Shuttle flight and is undergoing final evaluation for deployment on the Shuttle's first return to flight. This system will employ wireless accelerometer sensors that were qualified for other applications on previous Shuttle flights. These sensors will be deployed on the wing's leading edge to detect impacts on the RCC leading edge panels. The application of these methods will help to insure the continued integrity of the Shuttle wing's leading edge system as the Shuttle flights resume and until their retirement.

Eric I Madaras↗

NASA NTRS1982

Phenomenological and mechanics aspects of nondestructive evaluation and characterization by sound and ultrasound of material and fracture properties

Developments in fracture mechanics and elastic wave theory enhance the understanding of many physical phenomena in a mathematical context. Available literature in the material, and fracture characterization by NDT, and the related mathematical methods in mechanics that provide fundamental underlying principles for its interpretation and evaluation are reviewed. Information on the energy release mechanism of defects and the interaction of microstructures within the material is basic in the formulation of the mechanics problems that supply guidance for nondestructive evaluation (NDE).

Fu, L. S. W.↗

DOE OSTI2024

Assessment of Machine Learning for Ultrasonic Nondestructive Evaluation of Alkali–Silica Reaction in Concrete

Alkali–silica reaction (ASR) is a type of material degradation in concrete structures that leads to concrete cracking and rebar corrosion, thereby reducing the material’s structural integrity and the overall structure’s lifetime and raising safety concerns. Ultrasonic nondestructive evaluation (NDE) has been proven to be a valuable technique for assessing concrete properties and monitoring ASR progression in concrete. However, the deployment and analysis of ultrasonic NDE and its data requires specialized expertise, often relying on the engineer’s subjective interpretation. With the surge in computational power, artificial intelligence (AI) and machine learning (ML) algorithms have become popular in automating NDE data analysis. Various industrial sectors are increasingly adopting ML algorithms for NDE data analysis with a growing emphasis on AI–assisted automation. Regulatory agencies are also preparing for this technological shift, anticipating corresponding revisions in standards. Thus, there is an urgent need to identify the capabilities and limitations of current ML technologies for the evaluation of concrete material properties and damage status. Furthermore, the effects of various factors on ML model performance must be thoroughly investigated. The study summarized herein evaluated the effectiveness of two ML models (i.e., support vector regression (SVR) and deep neural network (DNN)) in predicting concrete material damage induced by ASR based on the long-term ultrasonic monitoring data. Four distinct concrete specimens were cast with artificially induced ASR, and over a period exceeding 500 days, ultrasonic signals and expansion data were continuously collected. For the SVR model, wave velocity and 12 other wave features were extracted from the ultrasonic signals, with 6 out of 13 features selected as input for the model. Different combinations of training and testing datasets were designed to explore factors influencing prediction performance, including the range of data within training and testing sets, in addition to various signal preprocessing methodologies. These findings suggest the importance of using a training dataset with a broader data range compared with testing datasets for improved model performance alongside consistent signal preprocessing across datasets.

36 MATERIALS SCIENCE↗

NASA NTRS1992

Nondestructive evaluation of ceramic and metal matrix composites for NASA's HITEMP and enabling propulsion materials programs

In a preliminary study, ultrasonic, x-ray opaque, and fluorescent dye penetrants techniques were used to evaluate and characterize ceramic and metal matrix composites. Techniques are highlighted for identifying porosity, fiber alignment, fiber uniformity, matrix cracks, fiber fractures, unbonds or disbonds between laminae, and fiber-to-matrix bond variations. The nondestructive evaluations (NDE) were performed during processing and after thermomechanical testing. Specific examples are given for Si3N4/SiC (SCS-6 fiber), FeCrAlY/Al2O3 fibers, Ti-15-3/SiC (SCS-6 fiber) materials, and Si3N4/SiC (SCS-6 fiber) actively cooled panel components. Results of this study indicate that the choice of the NDE tools to be used can be optimized to yield a faithful and accurate evaluation of advanced composites.

Generazio, Edward R.↗

DOE OSTI2025

Nondestructive Evaluation of Concrete: Elastic Property Imaging Through Full Waveform Inversion

Concrete is a major construction material worldwide and plays a crucial role in the nuclear industry. The elastic properties of concrete are prone to change and degrade while in service, as it is often subjected to extreme operational and environmental conditions. An accurate evaluation of concrete's elastic properties is thus essential to ensure structural integrity and safety. This is especially true for concrete in nuclear power plants, where irradiation effects significantly impact concrete mechanical properties. There are various methods to assess these properties, with ultrasound-based techniques showing high potential due to their nondestructive nature, cost-effectiveness, and safety. While several nondestructive evaluation methods exist, most rely on idealizations such as assuming homogeneous material and plane wavefronts. In this work, we address these issues by introducing an ultrasound-based nondestructive method aimed at reconstructing spatially varying images of concrete mechanical properties. By accurately modeling wave physics, including scattering and reflection, we overcome several of the aforementioned idealizations and aim to utilize the full waveform for imaging material properties through depth, resulting in more reliable images. Full waveform inversion (FWI) was first introduced by geophysicists to reconstruct subsurface elastic property images. The goal is to minimize the difference between simulated and recorded wavefield signals, often through gradient-based optimization algorithms. While FWI is primarily conducted using the acoustic approximation of the wave equation, few works focus on elastic FWI, where the goal is to reconstruct images of not only the pressure wave speed but also the shear wave speed and density (or their equivalents). This work explores the potential of using elastic FWI to predict concrete mechanical properties as an initial effort for a more accurate monitoring of concrete conditions in service. Reconstructing images of different elastic parameters enables more specificity and accurate condition diagnosis. This paper will detail this approach and provide examples demonstrating the effectiveness of elastic FWI in reconstructing comprehensive maps of concrete mechanical properties.

42 - ENGINEERING↗

NASA NTRS1974

Nondestructive evaluation of electroformed outer shells for regeneratively cooled thrust chambers

Electroforming is presently a prime technique for producing the outer jackets of regeneratively cooled thrust chambers for rocket engines. Good bond integrity of the electroformed joints adjacent to the coolant passages is important to the useful service life of these aerospace systems. This investigation demonstrated that nondestructive evaluation techniques such as ultrasonic 'C' scan, holography, and acoustic emission are capable of detecting low integrity bonds which could lead to premature failures in the subject hardware.

Malone, G. A.↗

NASA NTRS1978

Use of an ultrasonic-acoustic technique for nondestructive evaluation of fiber composite strength

Details of the method used to measure the stress wave factor are described. Frequency spectra of the stress waves are analyzed in order to clarify the nature of the wave phenomena involved. The stress wave factor was measured with simple contact probes requiring only one-side access to a part. This is beneficial in nondestructive evaluations because the waves can run parallel to fiber directions and thus measure material properties in directions assumed by actual loads. The technique can be applied where conventional through transmission techniques are impractical or where more quantitative data are required. The stress wave factor was measured for a series of graphite/polyimide composite panels, and results obtained are compared with through transmission immersion ultrasonic scans.

Vary, A.↗

NASA NTRS1990

Acousto-ultrasonic nondestructive evaluation of materials using laser beam generation and detection

Presented in viewgraph format, the possibility of using laser generation and detection of ultrasound to replace piezoelectric transducers for the acousto-ultrasonic technique is advanced. The advantages and disadvantages of laser acousto-ultrasonics are outlined. Laser acousto-ultrasonics complements standard piezoelectric acousto-ultrasonics and offers non-contact nondestructive evaluation.

Huber, Robert D.↗

NASA NTRS2002

Efficient Nondestructive Evaluation of Prototype Carbon Fiber Reinforced Structures

Thermography inspection is an optic based technology that can reduce the time and cost required to inspect propellant tanks or aero structures fabricated from composite materials. Usually areas identified as suspect in the thermography inspection are examined with ultrasonic methods to better define depth, orientation and the nature of the anomaly. This combination of nondestructive evaluation techniques results in a rapid and comprehensive inspection of composite structures. Examples of application of this inspection philosophy to prototype will be presented. Methods organizing the inspection and evaluating the results will be considered.

Russell, Samuel S.↗

NASA NTRS2010

Nondestructive Evaluation (NDE) for Characterizing Oxidation Damage in Cracked Reinforced Carbon-Carbon

In this study, coated reinforced carbon-carbon (RCC) samples of similar structure and composition as that from the NASA space shuttle orbiter's thermal protection system were fabricated with slots in their coating simulating craze cracks. These specimens were used to study oxidation damage detection and characterization using nondestructive evaluation (NDE) methods. These specimens were heat treated in air at 1143 C and 1200 C to create cavities in the carbon substrate underneath the coating as oxygen reacted with the carbon and resulted in its consumption. The cavities varied in diameter from approximately 1 to 3mm. Single-sided NDE methods were used because they might be practical for on-wing inspection, while X-ray micro-computed tomography (CT) was used to measure cavity sizes in order to validate oxidation models under development for carbon-carbon materials. An RCC sample having a naturally cracked coating and subsequent oxidation damage was also studied with X-ray micro-CT. This effort is a follow-on study to one that characterized NDE methods for assessing oxidation damage in an RCC sample with drilled holes in the coating.

Roth, Don J.↗

NASA NTRS2009

Nondestructive Evaluation (NDE) for Characterizing Oxidation Damage in Cracked Reinforced Carbon-Carbon (RCC)

In this study, coated reinforced carbon-carbon (RCC) samples of similar structure and composition as that from the NASA space shuttle orbiter's thermal protection system were fabricated with slots in their coating simulating craze cracks. These specimens were used to study oxidation damage detection and characterization using nondestructive evaluation (NDE) methods. These specimens were heat treated in air at 1143 and 1200 C to create cavities in the carbon substrate underneath the coating as oxygen reacted with the carbon and resulted in its consumption. The cavities varied in diameter from approximately 1 to 3 mm. Single-sided NDE methods were used since they might be practical for on-wing inspection, while x-ray micro-computed tomography (CT) was used to measure cavity sizes in order to validate oxidation models under development for carbon-carbon materials. An RCC sample having a naturally-cracked coating and subsequent oxidation damage was also studied with x-ray micro-CT. This effort is a follow-on study to one that characterized NDE methods for assessing oxidation damage in an RCC sample with drilled holes in the coating.

Roth, Don J.↗

NASA NTRS2012

Nondestructive Evaluation of the J-2X Direct Metal Laser Sintered Gas Generator Discharge Duct

The J-2X program at NASA's Marshall Space Flight Center (MSFC) procured a direct metal laser sintered (DMLS) gas generator discharge duct from Pratt & Whitney Rocketdyne and Morris Technologies for a test program that would evaluate the material properties and durability of the duct in an engine-like environment. DMLS technology was pursued as a manufacturing alternative to traditional techniques, which used off nominal practices to manufacture the gas generator duct's 180 degree turn geometry. MSFC's Nondestructive Evaluation (NDE) Team performed radiographic, ultrasonic, computed tomographic, and fluorescent penetrant examinations of the duct. Results from the NDE examinations reveal some shallow porosity but no major defects in the as-manufactured material. NDE examinations were also performed after hot-fire testing the gas generator duct and yielded similar results pre and post-test and showed no flaw growth or development.

Esther, Elizabeth A.↗

NASA NTRS2016

An Assessment of Nondestructive Evaluation Capability for Complex Additive Manufacturing Aerospace Components

The primary focus of this work is to investigate some of the fundamental relationships between processing, mechanical testing, materials characterization, and NDE for additively manufactured (AM) components using the powder bed fusion direct melt laser sintered process. The goal is to understand the criticality of defects unique to the AM process and then how conventional nondestructive evaluation methods as well as some of the more non-traditional methods such as computed tomography, are effected by the AM material. Specific defects including cracking, porosity and partially/unfused powder will be addressed. Besides line-of-site NDE, as appropriate these inspection capabilities will be put into the context of complex AM geometries where hidden features obscure, or inhibit traditional NDE methods.

Walker, James↗

NASA NTRS2006

An Analysis of Nondestructive Evaluation Techniques for Polymer Matrix Composite Sandwich Materials

Structural sandwich materials composed of triaxially braided polymer matrix composite material face sheets sandwiching a foam core are being utilized for applications including aerospace components and recreational equipment. Since full scale components are being made from these sandwich materials, it is necessary to develop proper inspection practices for their manufacture and in-field use. Specifically, nondestructive evaluation (NDE) techniques need to be investigated for analysis of components made from these materials. Hockey blades made from sandwich materials and a flat sandwich sample were examined with multiple NDE techniques including thermographic, radiographic, and shearographic methods to investigate damage induced in the blades and flat panel components. Hockey blades used during actual play and a flat polymer matrix composite sandwich sample with damage inserted into the foam core were investigated with each technique. NDE images from the samples were presented and discussed. Structural elements within each blade were observed with radiographic imaging. Damaged regions and some structural elements of the hockey blades were identified with thermographic imaging. Structural elements, damaged regions, and other material variations were detected in the hockey blades with shearography. Each technique s advantages and disadvantages were considered in making recommendations for inspection of components made from these types of materials.

Cosgriff, Laura M.↗

NASA NTRS1994

The probability of flaw detection and the probability of false calls in nondestructive evaluation equipment

The space industry has developed many composite materials that have high durability in proportion to their weights. Many of these materials have a likelihood for flaws that is higher than in traditional metals. There are also coverings (such as paint) that develop flaws that may adversely affect the performance of the system in which they are used. Therefore there is a need to monitor the soundness of composite structures. To meet this monitoring need, many nondestructive evaluation (NDE) systems have been developed. An NDE system is designed to detect material flaws and make flaw measurements without destroying the inspected item. Also, the detection operation is expected to be performed in a rapid manner in a field or production environment. Some of the most recent video-based NDE methodologies are shearography, holography, thermography, and video image correlation.

Temple, Enoch C.↗

NASA NTRS2010

Nondestructive Evaluation Methods for the Ares I Common Bulkhead

A large scale bonding demonstration test article was fabricated to prove out manufacturing techniques for the current design of the NASA Ares I Upper Stage common bulkhead. The common bulkhead serves as the single interface between the liquid hydrogen and liquid oxygen portions of the Upper Stage propellant tank. The bulkhead consists of spin-formed aluminum domes friction stir welded to Y-rings and bonded to a perforated phenolic honeycomb core. Nondestructive evaluation methods are being developed for assessing core integrity and the core-to-dome bond line of the common bulkhead. Detection of manufacturing defects such as delaminations between the core and face sheets as well as service life defects such as crushed or sheared core resulting from impact loading are all of interest. The focus of this work will be on the application of thermographic, shearographic, and phased array ultrasonic methods to the bonding demonstration article as well as various smaller test panels featuring design specific defect types and geometric features.

Walker, James↗