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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

In Situ Guided Wave Structural Health Monitoring System

Aircraft engine rotating equipment operates at high temperatures and stresses. Noninvasive inspection of microcracks in those components poses a challenge for nondestructive evaluation. A low-cost, low-profile, high-temperature ultrasonic guided wave sensor was developed that detects cracks in situ. The transducer design provides nondestructive evaluation of structures and materials. A key feature of the sensor is that it withstands high temperatures and excites strong surface wave energy to inspect surface and subsurface cracks. The sol-gel bismuth titanate-based surface acoustic wave (SAW) sensor can generate efficient SAWs for crack inspection. The sensor is very thin (submillimeter) and can generate surface waves up to 540 C. Finite element analysis of the SAW transducer design was performed to predict the sensor behavior, and experimental studies confirmed the results. The sensor can be implemented on structures of various shapes. With a spray-coating process, the sensor can be applied to the surface of large curvatures. It has minimal effect on airflow or rotating equipment imbalance, and provides good sensitivity.

Zhao, George↗
NASA NTRSDate not supplied

TPSAS-NF1676L-12156-DND

The IVHM project recommends nine priorities for future IVHM research. Strain measurement technology is one of the nine recommendations. The Decadal Survey of Civil Aeronautics: Foundation for the Future, identified IVHM as the top NASA and national priority within the area of materials and structures. The survey also identified IVHM systems that warrant attention over the next decade such as “locally self-powered, wireless microelectromechanical sensors of various types tiny enough that very large numbers of sensors become practical.” Standard strain gages have been used to detect cracks in aircraft, and have been used to monitor load conditions and fatigue in airframes. High temperature devices will be able to monitor structural health in areas that are inaccessible today.

Cy Wilson↗
NASA NTRS2024

Considerations for Qualifying Reliable Eddy Current Array Technique for Detection of Backwall Cracks

A reliable nondestructive evaluation (NDE) technique provides minimum 90% probability of detection(POD) with 95% confidence for detection of cracklike flaws of a qualified size. In this case, the flaws are on backside of material. Eddy current array (ECA) probe or a single sensor eddy current probe in c-scanning mode is used for the flaw detection. Here, two geometries are considered for the test specimens. The two geometries are, a flat plate, and tube or pipe. The probe is assumed to be on outer diameter (OD)surface and the flaw is assumed to be at the inner diameter (ID) surface for tube inspection. The flaw and probe are on opposite side of wall thickness for inspection of plate material. The application may be used for acreage inspection or just for inspection of butt weld and heat affected zone (HAZ) in a tube, cylinder, or plate. The proposed approach is based on developing an instrument standardization or calibration procedure. Decision threshold of inspection procedure is determined using empirical qualification and noise data. The work explores essential parameters that are required to meet certain conditions to ensure reliable flaw detection. Physics-based simulation of eddy current array flaw detection is used to understand effect of essential parameters on signal response (amplitude and phase),and therefore flaw detectability. Simulation data is used to justify choice of calibration reference standard requirements and the qualification approach. An ECA technique qualification model is provided. The paper gives brief description of tasks to be completed for qualifying ECA technique for reliable detection of cracklike flaws.

Eddy current array inspection, nondestructive eval↗
NASA NTRS1996

Detecting Gear Tooth Fatigue Cracks in Advance of Complete Fracture

Results of using vibration-based methods to detect gear tooth fatigue cracks are presented. An experimental test rig was used to fail a number of spur gear specimens through bending fatigue. The gear tooth fatigue crack in each test was initiated through a small notch in the fillet area of a tooth on the gear. The primary purpose of these tests was to verify analytical predictions of fatigue crack propagation direction and rate as a function of gear rim thickness. The vibration signal from a total of three tests was monitored and recorded for gear fault detection research. The damage consisted of complete rim fracture on the two thin rim gears and single tooth fracture on the standard full rim test gear. Vibration-based fault detection methods were applied to the vibration signal both on-line and after the tests were completed. The objectives of this effort were to identify methods capable of detecting the fatigue crack and to determine how far in advance of total failure positive detection was given. Results show that the fault detection methods failed to respond to the fatigue crack prior to complete rim fracture in the thin rim gear tests. In the standard full rim gear test all of the methods responded to the fatigue crack in advance of tooth fracture; however, only three of the methods responded to the fatigue crack in the early stages of crack propagation.

Zakrajsek, James J.↗
NASA NTRS2005

Cracks in Flow Liners and Their Resolution

Cracks were detected in flow liners at the gimbal joints in the LH2 feedlines of the space shuttle's main engines. The cracks initiated at defects in the drainage slots of the flow liners and grew due to high cycle fatigue. Fracture mechanics analyses were conducted to evaluate the life of the liners. These analyses yielded extremely short lives in the presence of small surface or corner cracks. A high fidelity detection method, edge replication, was used to detect the very small cracks. The detected cracks were removed by polishing and the surface quality of the slots was reestablished to improve life of the liners.

Harris, C. E.↗
NASA NTRS1972

Detection of fiber cracking by acoustic emission.

A theoretical model is presented that relates acoustic emission to fiber cracking which occurs during a rising load tension test on a fiber reinforced composite. The percentage of broken fibers in an Al3Ni fiber reinforced aluminum was measured as a function of tensile strain by optical inspection of the polished surface of strained specimens. This information was used in conjunction with the proposed model to predict the acoustic emission response of the composite material. These predictions were compared with experimental observations, and a good agreement was obtained between the two sets of results. These results indicate that it is possible to relate acoustic emission quantitatively to the micromechanics of the deformation processes occurring within fiber reinforced composites, thereby demonstrating the applicability of acoustic emission to materials studies and also to nondestructive evaluation of the integrity of composite materials.

Harris, D. O.↗
NASA NTRS1989

Ultrasonic Detection Of Transply Cracks In Composites

Nondestructive testing technique measures densities of transply cracks and used to monitor propagation of such damage in advanced polymer-matrix composite materials. Acousto-ultrasonic measuring apparatus, used to measure stress-wave factors (SWF's) of undamaged specimens and specimens that contained various numbers of transply cracks. Acousto-ultrasonic technique of value in examining damage to material from one surface only.

Bowles, Kenneth J.↗
NASA NTRS1994

Application of Self Nulling Eddy Current Probe Technique to the Detection of Fatigue Crack Initiation and Control of Test Procedures

A major part of fracture mechanics is concerned with studying the initiation and propagation of fatigue cracks. This typically requires constant monitoring of crack growth during fatigue cycles and the knowledge of the precise location of the crack tip at any given time. One technique currently available for measuring fatigue crack length is the Potential Drop method. The method, however, may be inaccurate if the direction of crack growth deviates considerably from what was assumed initially or the curvature of the crack becomes significant. Another popular approach is to optically view the crack using a high magnification microscope, but this entails a person constantly monitoring it. The present proposed technique uses an automated scheme, in order to eliminate the need for a person to constantly monitor the experiment. Another technique under development elsewhere is to digitize an optical image of the test specimen surface and then apply a pattern recognition algorithm to locate the crack tip. A previous publication showed that the self nulling eddy current probe successfully tracked a simulated crack in an aluminum sample. This was the impetus to develop an online real time crack monitoring system. An automated system has been developed which includes a two axis scanner mounted on the tensile testing machine, the probe and its instrumentation and a personal computer (PC) to communicate and control all the parameters. The system software controls the testing parameters as well as monitoring the fatigue crack as it propagates. This paper will discuss the experimental setup in detail and demonstrate its capabilities. A three dimensional finite element model is utilized to model the magnetic field distribution due to the probe and how the probe voltage changes as it scans the crack. Experimental data of the probe for different samples under zero load, static load and high cycle fatigue load will be discussed. The final section summarizes the major accomplishments of the present work, the elements of the future R&D needs and the advantages and disadvantages of using this system in the laboratory and field.

Namkung, M.↗
NASA NTRS2008

Development of Eddy Current Techniques for Detection of Deep Fatigue Cracks in Multi-Layer Airframe Components

Thick, multi-layer aluminum structure has been widely used in aircraft design in critical wing splice areas. The multi-layer structure generally consists of three or four aluminum layers with different geometry and varying thickness, which are held together with fasteners. The detection of cracks under fasteners with ultrasonic techniques in subsurface layers away from the skin is impeded primarily by interlayer bonds and faying sealant condition. Further, assessment of such sealant condition is extremely challenging in terms of complexity of structure, limited access, and inspection cost. Although Eddy current techniques can be applied on in-service aircraft from the exterior of the skin without knowing sealant condition, the current eddy current techniques are not able to detect defects with wanted sensitivity. In this work a series of low frequency eddy current probes have been designed, fabricated and tested for this application. A probe design incorporating a shielded magnetic field sensor concentrically located in the interior of a drive coil has been employed to enable a localized deep diffusion of the electromagnetic field into the part under test. Due to the required low frequency inspections, probes have been testing using a variety of magnetic field sensors (pickup coil, giant magneto-resistive, anisotropic magneto-resistive, and spin-dependent tunneling). The probe designs as well as capabilities based upon a target inspection for sub-layer cracking in an airframe wing spar joint is presented.

Wincheski, Russell A.↗
NASA NTRS2003

TF41 Engine Fan Disk Seeded Fault Crack Propagation Test

Uncontained engine failures, although rare in occurrence, can have a catastrophic effect on aircraft performance and safety. Engine disk cracks can eventually lead to these type of failures. A number of techniques to detect engine disk cracks have been developed in recent years. However, these technologies have only been validated by disk spin pit tests, not actual engine tests. Due to this, a project was established to perform seeded fault engine tests on a TF41 engine disk fan. A defect was machined in the first stage fan disk of a TF41 engine. The disk was run in a spin pit to initiate a crack. Once initiated, the disk was run in an actual engine test facility. The engine was cycled by a number of start and stops with the goal of propagating the crack to disk burst through low cycle fatigue. Various crack detection techniques were installed on the engine and run real-time during the test to validate their abilities to detect disk cracks. These techniques were based on methods such as change in mass imbalance using vibration or shaft displacement, change in blade position, acoustic emission, and torsional resonance. At the completion of 4474 test cycles, the crack in the TF41 disk was determined to have grown approximately 0.025 inches. This was far less the predicted crack growth based on a fracture mechanics analysis and finite element stress analysis.

Lewicki, David G.↗
NASA NTRS1983

NDE detectability of fatigue type cracks in high strength alloys

Specimens suitable for investigating the reliability of production nondestructive evaluation (NDE) to detect tightly closed fatigue cracks in high strength alloys representative of those materials used in spacecraft engine/booster construction were produced. Inconel 718 was selected as representative of nickel base alloys and Haynes 188 was selected as representative of cobalt base alloys used in this application. Cleaning procedures were developed to insure the reusability of the test specimens and a flaw detection reliability assessment of the fluorescent penetrant inspection method was performed using the test specimens produced to characterize their use for future reliability assessments and to provide additional NDE flaw detection reliability data for high strength alloys. The statistical analysis of the fluorescent penetrant inspection data was performed to determine the detection reliabilities for each inspection at a 90% probability/95% confidence level.

Christner, B. K.↗