Results for “Thermal nondestructive evaluation” — Page 7

NASA NTRSDate not supplied

Delamination Depth Imaging for Quasi-Static and Fatigue Load Testing Using Passive Thermography

Passive thermography is used to monitor small increases in temperature resulting from delamination damage formation in composite hat-stiffened panels during both quasi-static and fatigue loading. It has been observed that rapid damage formation produces heating. This is composed of two heat generation components. The first component is an instantaneous response due to an irreversible thermoelastic strain release. The second component is mechanical heating, at the interface of failure, due to fracture damage. This produces a transient rise in temperature as the heat diffuses to the surface. The first component defines the thermal start time for the transient response. A one-dimensional thermal model is fitted to the data pixel by pixel, to produce imagery of the damage depth. The results are compared to ultrasonic and X-ray CT data.

Passive thermography↗

NASA NTRS1985

Micro-Raman spectroscopy: The analysis of micrometer and submicrometer atmospheric aerosols

A nondestructive method of molecular analysis which is required to fully utilize the information contained within a collected particle is discussed. Upper atmosphere reaction mechanisms are assessed when the chemical compounds, the use of micro-Raman spectrometric techniques to perform micron and submicron particle analysis was evaluated. The results are favorable and it is concluded that micron and submicron particles can be analyzed by the micron-Raman approach. Completely automatic analysis should be possible to 0.3 micro m. No problems are anticipated with photo or thermal decomposition. Sample and impurity fluorescence are the key source of background as they cannot be completely eliminated.

Klainer, S. M.↗

NASA NTRS2001

Damage Assessment of Creep Tested and Thermally Aged Metallic Alloys Using Acousto-Ultrasonics

In recent years emphasis has been placed on the early detection of material changes experienced in turbine powerplant components. During the scheduled overhaul of a turbine, the current techniques of examination of various hot section components aim to find flaws such as cracks, wear, and erosion, as well as excessive deformations. Thus far, these localized damage modes have been detected with satisfactory results. However, the techniques used to find these flaws provide no information on life until the flaws are actually detected. Major improvements in damage assessment, safety, as well as more accurate life prediction could be achieved if nondestructive evaluation (NDE) techniques could be utilized to sense material changes that occur prior to the localized defects mentioned. Because of elevated temperatures and excessive stresses, turbine components may experience creep behavior. As a result, it is desirable to monitor and access the current condition of such components. Research at the NASA Glenn Research Center involves developing and utilizing an NDE technique that discloses distributed material changes that occur prior to the localized damage detected by the current methods of inspection. In a recent study, creep processes in a nickel-base alloy were the life-limiting condition of interest, and the NDE technique was acousto-ultrasonics (AU). AU is an NDE technique that utilizes two ultrasonic transducers to interrogate the condition of a test specimen. The sending transducer introduces an ultrasonic pulse at a point on the surface of the specimen while a receiving transducer detects the signal after it has passed through the material. The goal of the method is to correlate certain parameters of the detected waveform to characteristics of the material between the two transducers. Here, the waveform parameter of interest is the attenuation due to internal damping for which information is being garnered from the frequency domain. The parameters utilized to indirectly quantify the attenuation are the ultrasonic decay rate as well as various moments of the frequency power spectrum. A new, user-friendly, graphical interface AU system was developed at NASA Glenn. This system is an all-inclusive, multifunction system that controls the sending and receiving ultrasonic transducers as well as all posttest signal analysis. The system's postprocessing software calculates the multiple parameters used to study the material of interest.

Gyekenyesi, Andrew L.↗

NASA NTRS2016

Large Area Nondestructive Evaluation of a Fatigue Loaded Composite Structure

Large area nondestructive evaluation (NDE) inspections are required for fatigue testing of composite structures to track damage initiation and growth. Of particular interest is the progression of damage leading to ultimate failure to validate damage progression models. In this work, passive thermography and acoustic emission NDE were used to track damage growth up to failure of a composite three-stringer panel. Fourteen acoustic emission sensors were placed on the composite panel. The signals from the array were acquired simultaneously and allowed for acoustic emission location. In addition, real time thermal data of the composite structure were acquired during loading. Details are presented on the mapping of the acoustic emission locations directly onto the thermal imagery to confirm areas of damage growth leading to ultimate failure. This required synchronizing the acoustic emission and thermal data with the applied loading. In addition, processing of the thermal imagery which included contrast enhancement, removal of optical barrel distortion and correction of angular rotation before mapping the acoustic event locations are discussed.

Joseph N Zalameda↗

NASA NTRS1991

Infrared technology XVII; Proceedings of the Meeting, San Diego, CA, July 22-26, 1991

Recent advances in IR technologies and their application to all types of IR systems are reported focusing on the JPL Space Infrared Telescope Facility (SIRTF), JPL instruments and systems for observation of earth and the atmosphere, staring arrays and thermal imaging, ten-year updates of IR techniques, infrared in the USSR, simulation and testing, focal-plane and optical technologies, and military and scientific applications. Particular attention is given to SIRTF stray light analysis, SIRTF focal-plane technologies, long-wave IR detectors based on III-V materials, IR lidars for atmospheric remote sensing, a firefly system concept, a high-fill-factor monolithic IR image sensor, atmospheric laser-transmission tables simply generated, ORION semiconductor optical detectors, postprocessing of thermograms in IR nondestructive testing, evaluation of the IR signature of dynamic air targets, the current status of InGaAs detector arrays for 1-3 microns, a dual-band optical system for IR multicolor signal processing, and blackbody radiators for field calibration.

Andresen, Bjorn F.↗

NASA NTRS1998

Single-Transducer, Ultrasonic Imaging Method for High-Temperature Structural Materials Eliminates the Effect of Thickness Variation in the Image

NASA Lewis Research Center's Life Prediction Branch, in partnership with Sonix, Inc., and Cleveland State University, recently advanced the development of, refined, and commercialized an advanced nondestructive evaluation (NDE) inspection method entitled the Single Transducer Thickness-Independent Ultrasonic Imaging Method. Selected by R&D Magazine as one of the 100 most technologically significant new products of 1996, the method uses a single transducer to eliminate the superimposing effects of thickness variation in the ultrasonic images of materials. As a result, any variation seen in the image is due solely to microstructural variation. This nondestructive method precisely and accurately characterizes material gradients (pore fraction, density, or chemical) that affect the uniformity of a material's physical performance (mechanical, thermal, or electrical). Advantages of the method over conventional ultrasonic imaging include (1) elimination of machining costs (for precision thickness control) during the quality control stages of material processing and development and (2) elimination of labor costs and subjectivity involved in further image processing and image interpretation. At NASA Lewis, the method has been used primarily for accurate inspections of high temperature structural materials including monolithic ceramics, metal matrix composites, and polymer matrix composites. Data were published this year for platelike samples, and current research is focusing on applying the method to tubular components. The initial publicity regarding the development of the method generated 150 requests for further information from a wide variety of institutions and individuals including the Federal Bureau of Investigation (FBI), Lockheed Martin Corporation, Rockwell International, Hewlett Packard Company, and Procter & Gamble Company. In addition, NASA has been solicited by the 3M Company and Allison Abrasives to use this method to inspect composite materials that are manufactured by these companies.

Roth, Don J.↗

NASA NTRS2001

Characterization of Ceramic Matrix Composite Combustor Components: Pre and Post Exposure

The pursuit of lower emissions and higher performance from gas turbine engines requires the development of innovative concepts and the use of advanced materials for key engine components. One key engine component is the combustor, where innovative design and material improvements have the potential to lower emissions. Efforts to develop a High Speed Civil Transport with low emissions were focused on the evaluation of combustor concepts with liners fabricated from a ceramic matrix composite of silicon carbide fibers in a silicon carbide matrix (SiC/SiC). The evaluation of SiC/SiC composites progressed from simple coupons (to establish a first-order database and identify operant failure mechanisms and damage accumulation processes), to feature-based subelements (to assess fabricability and in situ material response), to actual components (to assess structural integrity, dimensional, and compositional fidelity) tested under simulated engine conditions. As in the case of all evolutionary material and process work, a key element to resolving fabrication issues is the evaluation of witness areas taken from fabricated components before testing the actual component. The witness material from these components allowed microstructural and mechanical testing to be performed and compared to the ideal, flat panel, conditions and data that are typical of basic characterization. This also allowed samples of similar design to be taken from components after 115 hours of combustion exposure. Testing consisted of tensile, double notch shear, ring burst, and thermal conductivity that sampled various regions of the components. The evaluation of the witness material allowed an understanding of the fabrication process, highlighting critical issues, in an early phase of the learning curve development of these configuration and material unique parts. Residual property testing, after exposure, showed if degradation of the material under actual service conditions was occurring. This paper will present the results of this critical testing. Evaluations that consider the degree of complexity of the fabricated part were established to relate in situ performance to that of flat panel based coupons. Nondestructive evaluation was used throughout the evaluation process. These results will also be discussed as an aid in understanding the test results.

Ojard, G.↗

NASA NTRS1973

Investigation of laser holographic interferometric techniques for structure inspection

The application of laser holographic interferometric techniques for nondestructive inspection of material structures commonly used in aerospace works is investigated. Two types of structures, composite plate and solid fuel rocket engine motor casing, were examined. In conducting the experiments, both CW HeNe gas lasers and Q-switched ruby lasers were used as light sources for holographic recording setups. Different stressing schemes were investigated as to their effectiveness in generating maximum deformation at regions of structural weakness such as flaws and disbonds. Experimental results on stressing schemes such as thermal stressing, pressurized stressing, transducer excitation, and mechanical impact are presented and evaluated.

Chu, W. P.↗

NASA NTRS2005

Nondestructive Evaluation of Space Shuttle External Tank Foam

During launch of Shuttle Columbia, mission STS-107, a large piece of spray on foam insulation (SOFI) separated from the external tank left bipod ramp area impacting the shuttle orbiter left wing leading edge. "Analysis showed that this large piece of foam struck Columbia on the underside of the left wing after launch. Later, analysis showed that the larger piece struck Columbia on the underside of the left wing, around Reinforced Carbon-Carbon (RCC) panels 5 through 9, at 81.9 seconds after launch. Further photographic analysis revealed that the large foam piece was approximately 21 to 27 inches long and 12 to 18 inches wide and was moving at a relative velocity to the Shuttle stack of 625 to 840 feet per second (416 to 573 miles per hour) at the time of impact." This impact damaged the wing leading edge resulting in loss of orbiter thermal protection. The piece of errant foam was part of a bipod ramp which was designed to meet thermal and aerodynamic requirements in that region of the external tank (ET).

Thom, Robert L.↗

NASA NTRSDate not supplied

Parallelized Quadrupole Simulations of Thermographic Responses of Composites

Thermography has been shown to be a viable technique for inspection of composites. Model inversion of the thermography data requires a fast method for performing the forward problem. Viable numerical methods for the thermal response forward problem are finite element, finite difference and the quadrupole method. Normally both the finite element and finite difference methods solve for the thermal response in the time domain which limits one’s ability to increase the speed of the simulation by parallelization. In contrast, the quadrupole method solves for the Laplace transform of the thermal response. One of the features of the Laplace transform methodology is the solution at any discrete time is independent of the solution at all other times. Therefore, it is easy to separate into a set of independent calculations with each of the times of interest being performed in parallel. Additionally, the numeric inversion of the Laplace transform typically involves numerically solving for the Laplace transform at multiple Laplace frequencies. Each of those solutions are also independent of solutions at other frequencies and can be calculated in parallel. By parallelization of this method, it is possible to perform the simulations of three-dimensional configurations in seconds. When the input stimulus for thermal response is a delta function heat flux (a reasonable approximation for flash heating), the thermal response is smooth. For this case, it is possible to accurately estimate the thermal response at any time within a given time interval from a set of simulations separated by exponentially increasing time steps. From these simulations, it is possible to accurately interpolate to find the response at intermediate times by a spline interpolation of the logarithm of time versus logarithm of temperature. The thermal response with exponential time stepping is shown to produce values for the thermal response which are within 1% of values within the time interval. The simulations are compared to finite element simulations of the same inspection configurations. The simulations are also compared to the thermographic measurements on composites where shape and depth of the delaminations are obtained from other inspection methods.

Thermography↗

NASA NTRSDate not supplied

Parallelized Quadrupole Simulations of Thermographic Responses of Composites

Thermography has been shown to be a viable technique for inspection of composites. Model inversion of the thermography data requires a fast method for performing the forward problem. Viable numerical methods for the thermal response forward problem are finite element, finite difference and the quadrupole method. Normally both the finite element and finite difference methods solve for the thermal response in the time domain which limits one’s ability to increase the speed of the simulation by parallelization. In contrast, the quadrupole method solves for the Laplace transform of the thermal response. One of the features of the Laplace transform methodology is the solution at any discrete time is independent of the solution at all other times. Therefore, it is easy to separate into a set of independent calculations with each of the times of interest being performed in parallel. Additionally, the numeric inversion of the Laplace transform typically involves numerically solving for the Laplace transform at multiple Laplace frequencies. Each of those solutions are also independent of solutions at other frequencies and can be calculated in parallel. By parallelization of this method, it is possible to perform the simulations of three-dimensional configurations in seconds. When the input stimulus for thermal response is a delta function heat flux (a reasonable approximation for flash heating), the thermal response is smooth. For this case, it is possible to accurately estimate the thermal response at any time within a given time interval from a set of simulations separated by exponentially increasing time steps. From these simulations, it is possible to accurately interpolate to find the response at intermediate times by a spline interpolation of the logarithm of time versus logarithm of temperature. The thermal response with exponential time stepping is shown to produce values for the thermal response which are within 1% of values within the time interval. The simulations are compared to finite element simulations of the same inspection configurations. The simulations are also compared to the thermographic measurements on composites where shape and depth of the delaminations are obtained from other inspection methods.

Thermography↗

NASA NTRS2001

Detection and Characterization of Imperfections in Composite Pressure Vessels

The thermographic evaluation of composite structures for delaminations, disbonds, inclusions, porosity and microcracking has proven to be a valuable asset in the field of nondestructive testing. Coupling large area coverage, variable sensitivity and minimal surface contact with a photographic type image representation of structural anomalies; thermography has become a primary inspection method for composite structures. Thermography works well for locating both surface and subsurface defects in most composite systems ranging in thickness of up to 0.25 inch (0.64 cm) or more. The thermographic method for inspection of composite structures typically involves applying an external source of heat to the structure and then recording the changes in the surface heat profile manifested by embedded defects or by material property variations. If these temperature variations are large enough and an infrared camera with sufficient sensitivity is used, then the material or structural abnormality can be detected and referred back to its source. Interpreting the information given in a thermogram, can be a difficult task under ideal circumstances and extremely challenging in a real world setting. Variables including depth, thermal conductivity, orientation and size of the abnormality can all have a great influence on how its heat pattern will be seen by the imager. The work discussed in this paper illustrates how the microstructure of several commonly found defects in composite structures relate to their thermographic image counterpart. Two test cases are studied herein, including a large graphite/epoxy RP-1 fuel tank and a graphite composite cryogenic fuel feedline. The structures used in this study were designed to serve as manufacturing proof of concept specimens and to undergo hydroburst testing to verify manufacturing practices and structural design. Prior to hydrostatic testing the structures underwent 100% thermographic evaluation to ensure that no manufacturing or handling damage was present. Due to a large inclusion found in the feedline, it was pulled from service and dissected without performing the hydroproof The thermographic indications found in the RP-1 tank were below critical limits so it underwent a complete hydroproof loading series and finally a hydroburst. Following the hydroburst samples were cut from the tank in regions where thermography had located damage before the test. These regions were thermographically and then were cross-sectioned and photomicrographed.

Walker, James L.↗

NASA NTRS1997

Laser Shearographic Inspection for Debonds in Sprayed On Foam Insulation (SOFI)

Preliminary results of shearographic inspections of the test panels simulating the Space Shuttle's external tank (ET) spray on foam insulation (SOFI) are presented. Debonding of SOFI may introduce flight debris that may damage the orbiter's thermal protection system (TPS) exposing the orbiter (as well as the ET) to thermal loading. It is estimated that 90 percent of the TPS damage on the orbiter's 'belly' results from debonded SOFI during ascent. A series of test panels were fabricated, with programmed debonds of different geometries and sizes, to determine the sensitivity of shearography as a function of debond size, SOFI thickness,'and vacuum excitation. Results show that a Probability of Detection (POD) of 0.95 or better can be expected for debonds with a diameter equal to the SOFI thickness as less than 0.4-psi pressure reduction. More testing will be required to validate the laser shearography imaging process for certifying its use in nondestructive evaluation (NDE) of Space Shuttle space flight components.

Adams, F. W.↗

NASA NTRSDate not supplied

An Overview of Research in Nondestructive Evaluation at the National Aeronautics and Space Administration’s Langley Research Center

The primary focus of the nondestructive evaluation (NDE) effort at Langley Research Center (LaRC) is to pioneer advances in NDE and structural health monitoring (SHM) through fundamental scientific research, technology development, and transferring these to the scientific and aerospace communities. This research supports a variety of NASA missions in space operations, exploration and aeronautics. The work presented will focus on the development of advanced inspection systems to detect critical flaws in both metallic and non-metallic materials and structures for aerospace applications. The emphasis is on increasing the performance of inspection systems to provide defect detection and quantitative characterization of the material state. LaRC NDE utilizes expertise in computational ultrasonic, thermal and eddy current simulations to reduce measured responses to size and locations of flaws, establish technique limitations and optimize performance. This presentation will highlight research into five strategic areas: (1) The development of novel solutions using state-of-the-art NDE technologies such as eddy current, ultrasound, thermography and x-ray computed tomography; (2) Research in the development of unique NDE technologies such as terahertz, wavefield imaging and nonlinear ultrasound; (3) The application of both computational and analytic models to NDE problems; (4) The development of advanced analytic methods to interpret large complex data sets; and (5) Advanced methods of applying and interrogating sensors for structural health monitoring.

K Elliott Cramer↗

NASA NTRSDate not supplied

An Overview of Research in Nondestructive Evaluation at the National Aeronautics and Space Administration’s Langley Research Center

The primary focus of the nondestructive evaluation (NDE) effort at Langley Research Center (LaRC) is to pioneer advances in NDE and structural health monitoring (SHM) through fundamental scientific research, technology development, and transferring these to the scientific and aerospace communities. This research supports a variety of NASA missions in space operations, exploration and aeronautics. The work presented will focus on the development of advanced inspection systems to detect critical flaws in both metallic and non-metallic materials and structures for aerospace applications. The emphasis is on increasing the performance of inspection systems to provide defect detection and quantitative characterization of the material state. LaRC NDE utilizes expertise in computational ultrasonic, thermal and eddy current simulations to reduce measured responses to size and locations of flaws, establish technique limitations and optimize performance. This presentation will highlight research into five strategic areas: (1) The development of novel solutions using state-of-the-art NDE technologies such as eddy current, ultrasound, thermography and x-ray computed tomography; (2) Research in the development of unique NDE technologies such as terahertz, wavefield imaging and nonlinear ultrasound; (3) The application of both computational and analytic models to NDE problems; (4) The development of advanced analytic methods to interpret large complex data sets; and (5) Advanced methods of applying and interrogating sensors for structural health monitoring.

NDE↗

NASA NTRS1994

Modal Test Technology as Non-Destructive Evaluation of Space Shuttle Structures

Modal test and analysis Is being used for nondestructive evaluation of Space Shuttle structures. The purpose of modal testing is to measure the dynamic characteristics of a structure to extract its resonance frequencies, damping, and mode shapes. These characteristics are later compared to subsequently acquired characteristics. Changes in the modal characteristics indicate damage in the structure. Use of modal test technology as a damage detection tool was developed at JSC during the Shuttle acoustic certification program and subsequent test programs. The Shuttle Modal Inspection System was created in order to inspect areas that are impossible or impractical to inspect with conventional methods. Areas on which this technique has been applied include control surfaces, which are covered with thermal protection tiles, and the Forward Reaction Control Module, which is a frame structure that supports various tanks, thrusters, and fluid lines, which requires major disassembly to inspect. This paper traces the development of the technology, gives a status of its implementation on the Shuttle, explains challenges involved in implementing this type of inspection program, and suggests future improvements in data analysis and interpretation. Dual-use applications of the technology include inspections of bridges, oil-platforms, and aircraft.

Micheal S Grygler↗

NASA NTRS1973

Cyclic oxidation evaluation - Approaching application conditions.

Review of 1000 to 1200 C cyclic oxidation testing conducted on potential aircraft gas turbine Ni-, Co-, and Fe-base alloys. Furnace and burner rig testing are discussed, and the results are compared for selected alloys. The alloys fall into two groups, depending on their Cr and Al contents. One group forms mainly Cr2O3/chromite spinel scale(s), while the other forms alpha Al2O3/aluminate spinel scale(s). Spalling on thermal cycling leading to increased metal consumption is associated with the appearance of a chromite spinel. In the case of high-velocity burner rig tests this chromite forming tendency is reinforced by Cr2O3 vaporization depleting Cr in the alloy. In both types of tests, specific weight change is used as an indirect indicator of metal attack, since direct metal loss measurements require destructive analysis. An alternative nondestructive metal loss estimating parameter, based on a tentative mass balance gravimetric approach, shows some potential.

Barrett, C. A.↗

NASA NTRS1996

Crack Development in Cross-Ply Laminates Under Uniaxial Tension

This study addresses matrix-dominated failures in carbon fiber/polymer matrix composite laminates in a cross-ply lay-up. The events of interest are interlaminar fracture in the form of transverse cracks in the 90' plies and longitudinal splitting in the 0 deg plies and interlaminar fracture in the form of 0/90 delamination. These events were observed using various nondestructive evaluation (NDE) techniques during static tensile tests. Acoustic emission (AE) x radiography, and edge view microscopy were the principal ones utilized in a real-time environment. A comparison of the NDE results with an analytical model based on the classical linear fracture mechanics concept of strain energy release rate as a criterion for crack growth was performed. The virtual crack closure theory was incorporated with a finite element model to generate strain energy release rate curves for the analytical case. Celion carbon fiber/polyimide matrix (G30-500/PMR-15) was the material tested with cross-ply lay-ups of (0(2)/90(6))s and (0(4)/90(4))s. The test specimens contained thermally induced cracks caused by the high-temperature processing. The analytical model was updated to compensate for the initial damage and to study further accumulation by taking into account the crack interactions. By correlating the experimental and analytical data, the critical energy release rates were found for the observable events of interest.

Gyekenyesi, Andrew L.↗