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NASA NTRSDate not supplied

Three-Dimensional Reconstruction of Defects and Structures in Additively Manufactured Parts with Automated Serial Sectioning

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with complex components for space flight applications. Laser powderbed fusion (L-PBF) is a commonly used AM technology due to the ability to produce complex parts with fine feature resolution in a wide variety of alloys and applications. L-PBF, like many other manufacturing processes, can produce minor flaws in parts when in nominal operation as well as process-escape defects when process abnormalities occur. The effects of the flaws and methods of detecting the flaws are a subject of interest to understand the difficulties in detecting these flaws with current technology and how much risk the flaws or defects pose to potential flight parts. Using a RoboMet.3D automated serial sectioning system, seeded defects as well as minor process flaws can be imaged and reconstructed in three dimensions to compare to non-destructive evaluation (NDE) techniques, such as x-ray computed tomography (CT), neutron CT, and in-situ monitoring. The RoboMet automates the metallography process by automatically grinding, polishing, and imaging samples in a single system and providing the control data for NDE comparisons to know the real size of defects built into coupons. These comparisons provide an understanding behind the technological limitations of the NDE techniques for different alloys. The same serial sectioning methods have also been utilized to characterize the surfaces of parts to reconstruct the surfaces and take measurements of internal features not easily examined with non-destructive methods. Using the RoboMet, fine lattice structures built with L-PBF have been characterized to determine the actual thicknesses of struts and density of the lattice structures. These structures have been used as finer build supports for the L-PBF process, designs for fine catalysts, and other design considerations for small components. The RoboMet data helps to inform the modeling and design efforts around these fine components.

additive manufacturing↗

NASA NTRS2017

Calcium-Magnesium-Alumino-Silicates (CMAS) Reaction Mechanisms and Resistance of Advanced Turbine Environmental Barrier Coatings for SiC/SiC Ceramic Matrix Composites

Environmental barrier coatings (EBCs) and SiC/SiC ceramic matrix composites (CMCs) systems will play a crucial role in future turbine engines for hot-section component applications because of their ability to significantly increase engine operating temperatures, reduce engine weight and cooling requirements. The development of prime-reliant environmental barrier coatings is an essential requirement to enable the applications of the 2700-3000 F EBC - CMC systems. This presentation primarily focuses on the reaction mechanisms of advanced NASA environmental barrier coating systems, when in contact with Calcium-Magnesium Alumino-Silicates (CMAS) at high temperatures. Advanced oxide-silicate defect cluster environmental barrier coatings are being designed for ultimate balanced controls of the EBC temperature capability and CMAS reactivity, thus improving the CMAS resistance. Further CMAS mitigation strategies are also discussed.

Environmental barrier coatings (EBCs)↗

NASA NTRS2001

Coriolis-force-induced trajectory and endpoint deviations in the reaching movements of labyrinthine-defective subjects

When reaching movements are made during passive constant velocity body rotation, inertial Coriolis accelerations are generated that displace both movement paths and endpoints in their direction. These findings directly contradict equilibrium point theories of movement control. However, it has been argued that these movement errors relate to subjects sensing their body rotation through continuing vestibular activity and making corrective movements. In the present study, we evaluated the reaching movements of five labyrinthine-defective subjects (lacking both semicircular canal and otolith function) who cannot sense passive body rotation in the dark and five age-matched, normal control subjects. Each pointed 40 times in complete darkness to the location of a just extinguished visual target before, during, and after constant velocity rotation at 10 rpm in the center of a fully enclosed slow rotation room. All subjects, including the normal controls, always felt completely stationary when making their movements. During rotation, both groups initially showed large deviations of their movement paths and endpoints in the direction of the transient Coriolis forces generated by their movements. With additional per-rotation movements, both groups showed complete adaptation of movement curvature (restoration of straight-line reaches) during rotation. The labyrinthine-defective subjects, however, failed to regain fully accurate movement endpoints after 40 reaches, unlike the control subjects who did so within 11 reaches. Postrotation, both groups' movements initially had mirror image curvatures to their initial per-rotation reaches; the endpoint aftereffects were significantly different from prerotation baseline for the control subjects but not for the labyrinthine-defective subjects reflecting the smaller amount of endpoint adaptation they achieved during rotation. The labyrinthine-defective subjects' movements had significantly lower peak velocity, higher peak elevation, lower terminal velocity, and a more vertical touchdown than those of the control subjects. Thus the way their reaches terminated denied them the somatosensory contact cues necessary for full endpoint adaptation. These findings fully contradict equilibrium point theories of movement control. They emphasize the importance of contact cues in adaptive movement control and indicate that movement errors generated by Coriolis perturbations of limb movements reveal characteristics of motor planning and adaptation in both healthy and clinical populations.

NASA Discipline Neuroscience↗

NASA NTRS2015

Effect of Buckling Modes on the Fatigue Life and Damage Tolerance of Stiffened Structures

The postbuckling response and the collapse of composite specimens with a co-cured hat stringer are investigated experimentally and numerically. These specimens are designed to evaluate the postbuckling response and the effect of an embedded defect on the collapse load and the mode of failure. Tests performed using controlled conditions and detailed instrumentation demonstrate that the damage tolerance, fatigue life, and collapse loads are closely tied with the mode of the postbuckling deformation, which can be different between two nominally identical specimens. Modes that tend to open skin/stringer defects are the most damaging to the structure. However, skin/stringer bond defects can also propagate under shearing modes. In the proposed paper, the effects of initial shape imperfections on the postbuckling modes and the interaction between different postbuckling deformations and the propagation of skin/stringer bond defects under quasi-static or fatigue loads will be examined.

Davila, Carlos G.↗

NASA NTRS1985

Solar maximum thermal surface assessment

The inflight repair of the Solar Maximum Spacecraft provided the first opportunity to make actual measurements of thermal control surfaces after 4 years exposure in low Earth orbit. Defective hardware was replaced by astronauts and returned to Earth while protected from reentry damage in the Shuttle Payload bay. A preliminary thermal surface assessment was made soon after retrieval in support of Space Telescope and other current spacecraft programs. This included visual examination and measurement of Kapton and Teflon film to determine change in thermal radiative properties after 4 years exposure to solar radiation and reaction with atomic oxygen. Comparative measurements were made with a portable solar reflectometer used for inspection of spacecraft hardware. Post flight measurements and observations reveal significant surface changes that further confirm Kapton mass loss predictions made prior to Solar Maximum repair. Details of thermal surface application, measurements and experimental results are presented and discussed.

Rhoads, G. D.↗

NASA NTRS1996

The growth of low band-gap InAs on (111)B GaAs substrates

Growth on the (111)B orientation exhibits a number of advantageous properties as compared to the (100) during the early stages of strained-layer epitaxy. In accordance with a developing model of nucleation and growth, we have deposited thin (60 A - 2500 A), fully relaxed InAs films on (111)B GaAs substrates. Although thicker InAs films are subject to the formation of twin defects common to epitaxy on the (111)B orientation, appropriate control of the growth parameters can greatly minimize their density. Using this knowledge base, InAs films up to 2 microns in thickness with improved morphology and structural quality have been grown on (111)B GaAs substrates.

Welser, Roger E.↗

NASA NTRS1995

The Growth of Low Band-Gap InAs on (111)B GaAs Substrates

Weiser, R. E.↗

NASA NTRS1990

Actuator selection for large space structures

The paper discusses the process of selecting the actuator locations and the determination of the required number of actuators for large space structures. The selection is based on the definitions of the degree of controllability, the independence of actuators, and the effectiveness of the individual actuators. An algorithm is developed that can be used for the selection of the essential number of actuators and for finding some defects of the system, such as the insuffiency of the available actuator locations for effective control of the whole system or a too crowded frequency distribution. The efficiency of the algorithm was demonstrated by an application to the Space Station.

Reddy, A. S. S. R.↗

NASA NTRS2012

HCIT Broadband Contrast Performance Sensitivity Studies

One of the important milestones of the TPF Coronagraph project is to demonstrate the ability to predict the performance sensitivities of the system at levels consistent with exo-planet detection requirement. We want to gain some general understanding about the potentials and the limitations of the current single-Deformable-Mirror (DM) High-contrast imaging testbed (HCIT) system through modeling and simulations. Specifically, we want to understand the effects of some common errors on the EFC-based control of e-field over a half dark-hole region and broadband contrast. Investigated errors include: (1) Absorbing particles on a flat-mirror (2) Defects on the Occulter surface (3) Dead actuators on the DM. We also investigated the effects of control bandwidth on the broadband contrast. We used a MACOS-based simulation algorithm which (1) combines a ray trace, diffraction model, & a broadband wavefront control algorithm (2) is capable of performing full three-dimensional near-field diffraction analysis

exoplanets↗

NASA NTRS1990

Numerical derivative techniques for trajectory optimization

The adoption of robust numerical optimization techniques in trajectory simulation programs has resulted in powerful design and analysis tools. These trajectory simulation/optimization programs are widely used, and a representative list includes the GTS system, the POST program, and newer collocation methods such as OTIS and FONPAC. All of these programs rely on optimization algorithms which require objective function and constraint gradient data during the iteration process. However, most trajectory optimization problems lack simple analytical expressions for these derivatives. In the general case a function evaluation involves integrating aerodynamic, propulsive, and gravity forces over multiple trajectory phases with complex control models. With the newer collocation methods, the integration is replaced by defect constraints and cubic approximations for the state. While analytic gradient expressions can sometimes be derived for trajectory optimization problems, the derivation is cumbersome, time consuming, and prone to mistakes. Fortunately, an alternate method exists for the gradient evaluation, namely finite difference approximations. In this paper some finite difference gradient techniques developed for use with the GTS system are presented. These techniques include methods for computing first and second partial derivatives of single and multiple sets of functions. A key feature of these methods is an error control mechanism which automatically adjusts the perturbation size to obtain accurate derivative values.

Hallman, Wayne P.↗

NASA NTRS2017

Correlations Among Microstructure, Morphology, Chemistry, and Isotopic Systematics of Hibonite in CM Chondrites

Introduction: Hibonite is a primary refractory phase occurring in many CAIs, typically with spinel and perovskite. Our microstructural studies of CAIs from carbonaceous chondrites reveal a range of stacking defect densities and correlated non-stoichiometry in hibonite. We also conducted a series of annealing experiments, demonstrating that the Mg-Al substitution stabilized the formation of defect-structured hibonite. Here, we continue a detailed TEM analysis of hibonite-bearing inclusions from CM chondrites that have been well-characterized isotopically. We examine possible correlations of microstructure, morphology, mineralogy, and chemical and isotopic systematics of CM hibonites in order to better understand the formation history of hibonite in the early solar nebula. Methods: Fifteen hibonite-bearing inclusions from the Paris CM chondrite were analyzed using a JEOL 7600F SEM and a JEOL 8530F electron microprobe. In addition to three hibonite-bearing inclusions from the Murchison CM chondrite previously reported, we selected three inclusions from Paris, Pmt1-6, 1-9, and 1-10, representing a range of 26Al/27Al ratios and minor element concentrations for a detailed TEM study. We extracted TEM sections from hibonite grains using a FEI Quanta 3D field emission gun SEM/FIB. The sections were then examined using a JEOL 2500SE field-emission scanning TEM equipped with a Thermo-Noran thin window EDX spectrometer. Results and Discussion: A total of six hibonite-bearing inclusions, including two platy hibonite crystals (PLACs) and four spinel-hibonite inclusions (SHIBs), were studied. There are notable differences in chemical and isotopic compositions between the inclusions (Table 1), indicative of their different formation environment or timing. Our TEM observations show perfectly-ordered, stoichiometric hibonite crystals without stacking defects in two PLACs, 2-7-1 and 2-8-2, and in three SHIBs, Pmt1-6, 1-9, and 1-10. In contrast, SHIB 1-9-5 hibonite grains contain a low density of stacking defects linked to an increase in MgO contents, indicating complex, disordered intergrowths of stoichiometric and MgO-enriched hibonites. From the data collected to date, we find no clear correlation between the microstructures of hibonite and its morphological and mineralogical types that reflect distinct chemical and isotopic systematics [6-8,10]. Interestingly, the presence of no or few stacking defects in hibonite from the PLACs and SHIBs are in contrast to our experimental studies that produced very high densities of stacking defects in hibonite [3-5]. Unlike our experi-ments, electron microprobe data from the PLACs and SHIBs hibonite grains show a strong correlation between (Ti4++Si4+) and Mg2+ cations, suggesting that coupled substitutions of (Ti4++Mg2+) and (Si4++Mg2+) for 2Al3+ inhibit the formation of defect-structured hibonite. However, our experimental studies suggest that kinetics (e.g., cooling rate) or other thermal effects also exert a strong control on the microstructures and chemical compositions of hibonite. In Pmt1-6, elongated perovskite grains present at the hibonite grain boundaries display (121) twinning, indicative of a fast cooling (>50degC/min) after high-temperature events. Therefore, the nebular microstructural characteristics of hibonite, at least in this inclusion, would not have destroyed by subsequent high-temperature annealing. Conclusions: Our TEM observations thus far show no clear correlation in microstructures, morphological and mineralogical characteristics, and chemical and isotopic systematics of hibonites from CM chondrites. The observed variation in stacking defect densities in the hibonites may be controlled by thermal processes in the early solar nebula. A detailed TEM analysis of additional CM hibonite samples is underway to evaluate this hypothesis.

Han, J.↗

NASA NTRS2005

NASA Tech Briefs, November 2005

Topics covered include: Laser System for Precise, Unambiguous Range Measurements; Flexible Cryogenic Temperature and Liquid-Level Probes; Precision Cryogenic Dilatometer; Stroboscopic Interferometer for Measuring Mirror Vibrations; Some Improvements in H-PDLCs; Multiple-Bit Differential Detection of OQPSK; Absolute Position Encoders With Vertical Image Binning; Flexible, Carbon-Based Ohmic Contacts for Organic Transistors; GaAs QWIP Array Containing More Than a Million Pixels; AutoChem; Virtual Machine Language; Two-Dimensional Ffowcs Williams/Hawkings Equation Solver; Full Multigrid Flow Solver; Doclet To Synthesize UML; Computing Thermal Effects of Cavitation in Cryogenic Liquids; GUI for Computational Simulation of a Propellant Mixer; Control Program for an Optical-Calibration Robot; SQL-RAMS; Distributing Data from Desktop to Hand-Held Computers; Best-Fit Conic Approximation of Spacecraft Trajectory; Improved Charge-Transfer Fluorescent Dyes; Stability-Augmentation Devices for Miniature Aircraft; Tool Measures Depths of Defects on a Case Tang Joint; Two Heat-Transfer Improvements for Gas Liquefiers; Controlling Force and Depth in Friction Stir Welding; Spill-Resistant Alkali-Metal-Vapor Dispenser; A Methodology for Quantifying Certain Design Requirements During the Design Phase; Measuring Two Key Parameters of H3 Color Centers in Diamond; Improved Compression of Wavelet-Transformed Images; NASA Interactive Forms Type Interface - NIFTI; Predicting Numbers of Problems in Development of Software; Hot-Electron Photon Counters for Detecting Terahertz Photons; Magnetic Variations Associated With Solar Flares; and Artificial Intelligence for Controlling Robotic Aircraft.

Source record↗

NASA NTRS1972

Acoustic emission used as weld quality monitor

Acoustic emission technique is described for use as quality control tool in nondestructive inspection of welds. Stress mounts around weld defect until it exceeds yield strength of material. Pressure wave relieving the stress is emitted and followed by oscillations caused by multiple reflections. Acoustic emissions are then detected by sensor similar to ultrasonic sensor.

Jolly, W. O.↗

NASA NTRS1990

Model-free distributed learning

Model-free learning for synchronous and asynchronous quasi-static networks is presented. The network weights are continuously perturbed, while the time-varying performance index is measured and correlated with the perturbation signals; the correlation output determines the changes in the weights. The perturbation may be either via noise sources or orthogonal signals. The invariance to detailed network structure mitigates large variability between supposedly identical networks as well as implementation defects. This local, regular, and completely distributed mechanism requires no central control and involves only a few global signals. Thus it allows for integrated on-chip learning in large analog and optical networks.

Dembo, Amir↗

NASA NTRS1992

Room Temperature Cyclic Deformation Behavior of Cast and Extruded NiAl

The fully reversed, strain controlled fatigue behavior of cast and extruded NiAl was evaluated at room temperature for plastic strain ranges of 0.0006 to 0.0002 to provide baseline data on the fatigue life of NiAl and to investigate whether the low ductility of NiAl would result in poor low-cycle fatigue behavior. Except at the smallest plastic strain range investigated, NiAl work hardened continuously until failure with a final fracture stress under cyclic conditions which was at least 60 percent greater than the monotonic fracture strength of NiAl. Fatigue fracture initiation occurred at large internal tear-shaped pores, and fatigue life was controlled or limited by the presence of these processing-related defects. Even with the processing defects present in this material and the limited ductility of NiAl in general, cast and extruded NiAl exhibited much greater fatigue life at room temperature than comparable B2 ordered compounds when compared on a strain range basis.

Noebe, R. D.↗

NASA NTRS1998

Simulated Bladed MMC Disk LCF Validation

The goal of this program was to evaluate the low cycle fatigue behavior of an SCS-6/Ti-6Al-4V sub-component under bi-axial loading conditions at 316 C(600 F). A simulated bladed TMC disk was designed having thirty four blades representing the number that would be used in Allied Signal's JTAGG II impeller. The outer diameter of the bladed ring was 254 mm (10.0 inch) and the inner diameter 114.3 mm (4.50 inch). The outer and inner diameter of the composite zone was 177.8 mm (7.00 inch) and 127.O mm(5.00 inch) respectively. Stress analysis showed that the fatigue life of the bladed composite ring would be about 12000 cycles for the test conditions applied. A modal analysis was conducted which showed that the blades would have sufficient life margin from dynamic excitation. The arbor design was the same as that employed in the spin-to burst test of NAS3-27027. A systematic stress analysis of each part making up the arbor was undertaken to assure the design would meet the low cycle fatigue requirements of the program. The Textron Systems grooved foil-fiber process was chosen to make the SCS-6/Ti-6Al-4V core ring based on the success they had in contract NAS3-27027. Fiber buckling, however, was observed at several locations in the first ring made which rendered it unsuitable for spin testing. The fiber buckling was attributed to cracking of the graphite tooling during the consolidation process. On this basis a second ring was made but it too contained fiber buckling defects. Analysis by Textron indicated that the fiber buckling was most likely due to poor placement of the SCS-6 fiber in the etched grooves of the Ti-6Al-4V foil. This was also a contributor to the defects in the first ring. Since there was little indication of control in the process to manufacture a quality ring a third attempt at making a ring was not undertaken.

Merrick, H. F.↗

NASA NTRS2016

Development of a Fully Automated Guided Wave System for In-Process Cure Monitoring of CFRP Composite Laminates

A guided wave-based in-process cure monitoring technique for carbon fiber reinforced polymer (CFRP) composites was investigated at NASA Langley Research Center. A key cure transition point (vitrification) was identified and the degree of cure was monitored using metrics such as amplitude and time of arrival (TOA) of guided waves. Using an automated system preliminarily developed in this work, high-temperature piezoelectric transducers were utilized to interrogate a twenty-four ply unidirectional composite panel fabricated from Hexcel (Registered Trademark) IM7/8552 prepreg during cure. It was shown that the amplitude of the guided wave increased sharply around vitrification and the TOA curve possessed an inverse relationship with degree of cure. The work is a first step in demonstrating the feasibility of transitioning the technique to perform in-process cure monitoring in an autoclave, defect detection during cure, and ultimately a closed-loop process control to maximize composite part quality and consistency.

Hudson, Tyler B.↗

NASA NTRS1985

Nonstoichiometric defects in GaAs and the EL2 bandwagon

In the present paper, an attempt is made to formulate a common framework for a discussion of nonstoichiometric defects, especially EL2 and dislocations. An outline is provided of the most important settled and unsettled issues, taking into account not only fundamental interests, but also urgent needs in advancing IC technology. Attention is given to stoichiometry-controlled compensation, the expected role of melt stoichiometry in electrical conductivity for the basic atomic disorders, defect equilibria-dislocations and EL2, and current issues pertaining to the identification of EL2. It is concluded that nonstoichiometric defects play a critical role in the electronic properties of GaAs and its electronic applications. Very significant progress has been recently made in learning how to adjust melt stoichiometry in order to maximize its beneficial effects and minimize its detrimental ones.

Lagowski, J.↗