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At least 1,513 records · Page 84

Effective Defect Detection Using Instance Segmentation for NDI

Ultrasonic testing is a common Non-Destructive Inspection (NDI) method used in aerospace manufacturing. However, the complexity and size of the ultrasonic scans make it challenging to identify defects through visual inspection or machine learning models. Using computer vision techniques to identify defects from ultrasonic scans is an evolving research area. In this study, we used instance segmentation to identify the presence of defects in the ultrasonic scan images of composite panels that are representative of real components manufactured in aerospace. We used two models based on Mask- RCNN (Detectron 2) and YOLO 11 respectively. Additionally, we implemented a simple statistical pre-processing technique that reduces the burden of requiring custom-tailored pre-processing techniques. Our study demonstrates the feasibility and effectiveness of using instance segmentation in the NDI pipeline by significantly reducing data pre-processing time, inspection time, and overall costs.

computer vision techniques↗

Direct nanoscale mapping of open circuit voltages at local back surface fields for PERC solar cells

The open circuit voltage (V OC) is a critical and common indicator of solar cell performance as well as degradation, for panel down to lab-scale photovoltaics. Detecting V OC at the nanoscale is much more challenging, however, due to experimental limitations on spatial resolution, voltage resolution, and/or measurement times. Accordingly, in this work an approach based on Conductive Atomic Force Microscopy is implemented to directly detect the local V OC , notably for monocrystalline Passivated Emitter Rear Contact (PERC) cells which are the most common industrial-scale solar panel technology in production worldwide. This is demonstrated with cross-sectioned monocrystalline PERC cells around the entire circumference of a poly-Aluminum-Silicide via through the rear emitter. The V OC maps reveal a local Back Surface Field extending ~2 μm into the underlying p-type Si absorber due to Al in-diffusion as designed. Such high spatial resolution methods for photovoltaic performance mapping are especially promising for directly visualizing the effects of processing parameters, as well as identifying signatures of degradation for silicon and other solar cell technologies.

14 SOLAR ENERGY↗

Support for Reactor Operators in Case of Cyber-Security Threats (NEUP Final Report)

Increasing use of digital technology in nuclear power plants (NPPs) poses cyber-security as a crucial threat to public safety and to continuous energy production. Cyber-security risks are comprised of complex known and unknown interactions between various entities, system vulnerabilities, network protocols, human users and malicious attacks. There is little understanding or research geared towards plant operators’ response under cyber-security threats and operational procedures to cope with such threats. This is particularly critical when a cyber-security event masquerades as a safety incident or an evolving accident. Instead of leading operators to the remediation of the accident, the masked cyber event may lead them to circumvent the safety mechanisms of the plant. Given these challenges, the objective of this project is to develop a tool to characterize abnormal NPP events as “cyber” or “safety” incidents, and to further develop this tool as a real-time operator aid to assist in response to the incident. This NEUP Final Report summarizes the research efforts towards the above goals and the results in the following three aspects. First, a methodology for classifying abnormal NPP events as cyber-attacks or safety incidents was developed. This provides the basis for responding to potential cyber-attacks. In this methodology, the causal relationships between various variables (i.e., physical variables, network variables, and control variables) for a nuclear system under consideration are modeled using dynamic Bayesian networks. Based on observations of certain variables (i.e., the evidence), inference is performed to identify the state of hidden variables, which helps indicate the occurrence of cyber-attacks or safety incidents. The proposed methodology was applied to the full scope NPP simulator system at The Ohio State University as a case study. The result shows that the proposed methodology is capable of distinguishing between cyber-attacks and safety incidents. Second, a game-theoretic approach for responding to cyber-attacks on nuclear power plants was developed. This is the second major goal of the project, and the method is used to recommend optimal responses to reactor operators in the case of cyber-attacks. We consider two cases in this research. In the first case, the interaction between the defender (i.e., the reactor operator) and the attacker is modeled as a two-player, nonzero-sum, Markov game with an infinite time horizon. In the second case, we consider a semi-Markov game between the defender and the attacker within a finite time horizon. The model in the second case enables us to consider the time sensitive response of the defender. In each case, the method for deriving the Nash equilibrium is developed. The Nash Equilibrium of the game provides the valid prediction of both players’ actions because no single player can benefit from unilaterally deviating from the equilibrium policy if the other player adheres to his/hers, hence it provides the best response of the defender to cyber-attacks. The proposed method in each case is demonstrated through a simplified benchmark digital feedwater control system. Third, a prototype display is developed to integrate the above information. The prototype display depicts the communication information to the operator and incorporates the cyber-security tool developed by the team into the interface. It consists of the regular display in current control rooms, as well as a panel used to indicate the occurrence of cyber-attacks or safety events and a panel used to guide the operator’s response to detected cyber-attacks.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Continuous Processing of Carbon Foam Products Made from Coal at Atmospheric Pressure

The main goal of the project was to create a continuous manufacturing process for carbon foam that operates at atmospheric pressure and can generate well-formed carbon foam panels and lightweight aggregates. This objective was accomplished and has enabled a platform where carbon foam products can be manufactured at significantly reduced cost and cycle time relative to the conventional high-pressure batch process, which in turn can enable the manufacture of much larger volumes of carbon foam. All these features should enable carbon foam to enter much larger markets and create meaningful demand for U.S. coal. Carbon foam panels and aggregate both consisted of at least 70 weight percent carbon per program requirements (typical was over 90-wt%), and at least 51 weight percent of the carbon was to be coal derived (typical was over 90-wt% carbon was from coal). Analyses regarding life cycle, technoeconomics, and final technological gaps have been documented in separate reports. This final report documents the methods used to attain the main goal and describes the technical results.

01 COAL, LIGNITE, AND PEAT↗

Sequence, molecular properties, and chromosomal mapping of mouse lumican

PURPOSE. Lumican is a major proteoglycan of vertebrate cornea. This study characterizes mouse lumican, its molecular form, cDNA sequence, and chromosomal localization. METHODS. Lumican sequence was determined from cDNA clones selected from a mouse corneal cDNA expression library using a bovine lumican cDNA probe. Tissue expression and size of lumican mRNA were determined using Northern hybridization. Glycosidase digestion followed by Western blot analysis provided characterization of molecular properties of purified mouse corneal lumican. Chromosomal mapping of the lumican gene (Lcn) used Southern hybridization of a panel of genomic DNAs from an interspecific murine backcross. RESULTS. Mouse lumican is a 338-amino acid protein with high-sequence identity to bovine and chicken lumican proteins. The N-terminus of the lumican protein contains consensus sequences for tyrosine sulfation. A 1.9-kb lumican mRNA is present in cornea and several other tissues. Antibody against bovine lumican reacted with recombinant mouse lumican expressed in Escherichia coli and also detected high molecular weight proteoglycans in extracts of mouse cornea. Keratanase digestion of corneal proteoglycans released lumican protein, demonstrating the presence of sulfated keratan sulfate chains on mouse corneal lumican in vivo. The lumican gene (Lcn) was mapped to the distal region of mouse chromosome 10. The Lcn map site is in the region of a previously identified developmental mutant, eye blebs, affecting corneal morphology. CONCLUSIONS. This study demonstrates sulfated keratan sulfate proteoglycan in mouse cornea and describes the tools (antibodies and cDNA) necessary to investigate the functional role of this important corneal molecule using naturally occurring and induced mutants of the murine lumican gene.

NASA Discipline Cell Biology↗

Verification and Validation of a Three-Dimensional Composite Impact Model with Tabulated Input

A material model which incorporates several key capabilities which have been identified by the aerospace community as lacking in the composite impact models currently available in the commercial transient dynamic finite element code LS-DYNA® has been developed. The material model utilizes experimentally based tabulated input to define the evolution of plasticity and damage as opposed to specifying discrete input parameters (such as modulus and strength. The plasticity portion of the orthotropic, three-dimensional, macroscopic composite constitutive model is based on an extension of the Tsai-Wu composite failure model into a generalized yield function with a non-associative flow rule. The capability to account for the rate and temperature dependent deformation response of composites has also been incorporated into the material model. For the damage model, a strain equivalent formulation is utilized to allow for the uncoupling of the deformation and damage analyses. In the damage model, a diagonal damage tensor is defined to account for the directionally dependent variation of damage. However, the terms in the damage matrix are semi-coupled such that the damage in a particular coordinate direction is a function of the stresses and plastic strains in all of the coordinate directions. For the failure model, a tabulated approach is utilized in which a stress or strain based invariant is defined as a function of the location of the current stress state in stress space to define the initiation of failure, which allows an arbitrarily shaped failure surface to be defined. A systematic series of validation and verification studies, at a variety of length scales ranging from single element simulations to simulations of a flat panel impact test, have been performed to fully exercise and evaluate the capabilities of the developed model.

Impact↗

Integration and Test (I&T) Horror Stories and the Lessons Learned

I've been asked to be a presenter along with a panel of fellow NASA Electromagnetic Compatibility (EMC) engineers at this year's IEEE EMC & Signal and Power Integrity (SIPI) 2019 symposium. The topic I am asked to cover is in regards to I&T horror stories because of my 15 years of personal experience as an EMC test engineer with Code 549. I am planning on only having slides with photos of test methods we no longer use as well as cover some mishaps that have happened over the years both within my organization and throughout the space industry. Highlighting the mistakes that were made, the lessons learned from those incidents and how they've effected how we test today.

EMI↗

Workshop Report for Next-Gen AI for Proliferation Detection: Accelerating the Development and Use of Explainability Methods to Design AI Systems Suitable for Nonproliferation Mission Applications

Artificial intelligence (AI) promises powerful new capabilities in an expansive array of applications. One area is proliferation detection, where AI can provide transformative tools to achieve objectives currently inaccessible using conventional methods. In particular, AI affords the opportunity to use new indicators and process massive amounts of heterogeneous data that can increase sensitivity to proliferant activities and push proliferation detection to the earliest possible stages. However, existing AI tools are not ready to achieve such potential, falling short in regard to some important considerations involved in proliferation detection. One crucial aspect that requires improvement is the explainability of the most powerful AI algorithms (i.e., understanding how the algorithms actually arrive at their conclusions)-the lack of which prevents widespread adoption in national security missions. The Data Science and AI portfolio within the National Nuclear Security Administration's Office of Defense Nuclear Nonproliferation Research and Development is driving the development of next-generation AI for proliferation detection through the expertise and work of the national laboratories and partners in academia. The "Next-Gen AI for Proliferation Detection: Accelerating the Development and Use of Explainability Methods to Design AI Systems Suitable for Nonproliferation Mission Applications" workshop aimed to further this objective. The meeting was held virtually on Sept. 15-16, 2020 and included more than 170 participants, primarily from the national laboratories with additional contributions from university researchers and mission partners. Each day included a keynote presentation, four technical presentations about cutting-edge research in explainability, and a panel to explore considerations in applying explainability and developing AI systems that can accelerate the transition of emerging AI technologies among partners and end users to solve critical mission questions. This report summarizes the Next-Gen AI for Proliferation Detection workshop's content and findings.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

Aeroelastic Sizing for High-Speed Research (HSR) Longitudinal Control Alternatives Project (LCAP)

The Longitudinal Control Alternatives Project (LCAP) compared three high-speed civil transport configurations to determine potential advantages of the three associated longitudinal control concepts. The three aircraft configurations included a conventional configuration with a layout having a horizontal aft tail, a configuration with a forward canard in addition to a horizontal aft tail, and a configuration with only a forward canard. The three configurations were aeroelastically sized and were compared on the basis of operational empty weight (OEW) and longitudinal control characteristics. The sized structure consisted of composite honeycomb sandwich panels on both the wing and the fuselage. Design variables were the core depth of the sandwich and the thicknesses of the composite material which made up the face sheets of the sandwich. Each configuration was sized for minimum structural weight under linear and nonlinear aeroelastic loads subject to strain, buckling, ply-mixture, and subsonic and supersonic flutter constraints. This report describes the methods that were used and the results that were generated for the aeroelastic sizing of the three configurations.

Walsh, Joanne L.↗

VORTAB - A data-tablet method of developing input data for the VORLAX program

A method of developing an input data file for use in the aerodynamic analysis of a complete airplane with the VORLAX computer program is described. The hardware consists of an interactive graphics terminal equipped with a graphics tablet. Software includes graphics routines from the Tektronix PLOT 10 package as well as the VORTAB program described. The user determines the size and location of each of the major panels for the aircraft before using the program. Data is entered both from the terminal keyboard and the graphics tablet. The size of the resulting data file is dependent on the complexity of the model and can vary from ten to several hundred card images. After the data are entered, two programs READB and PLOTB, are executed which plot the configuration allowing visual inspection of the model.

Denn, F. M.↗

Terminal configured vehicle program: Test facilities guide

The terminal configured vehicle (TCV) program was established to conduct research and to develop and evaluate aircraft and flight management system technology concepts that will benefit conventional take off and landing operations in the terminal area. Emphasis is placed on the development of operating methods for the highly automated environment anticipated in the future. The program involves analyses, simulation, and flight experiments. Flight experiments are conducted using a modified Boeing 737 airplane equipped with highly flexible display and control equipment and an aft flight deck for research purposes. The experimental systems of the Boeing 737 are described including the flight control computer systems, the navigation/guidance system, the control and command panel, and the electronic display system. The ground based facilities used in the program are described including the visual motion simulator, the fixed base simulator, the verification and validation laboratory, and the radio frequency anechoic facility.

Source record↗

AGARD Fluid Dynamics Panel Symposium on Applications of Computational Fluid Dynamics in Aeronautics: Proceedings

The Fluid Dynamics Panel of AGARD arranged a Symposium on Applications of Computational Fluid Dynamics in Aeronautics, on 7 to 10 April 1986 in Aix-en-Provence, France. The purpose of the Symposium was to provide an assessment of the status of CFD in aerodynamic design and analysis, with an emphasis on emerging applications of advanced computational techniques to complex configurations. Sessions were devoted specifically to grid generation, methods for inviscid flows, calculations of viscous-inviscid interactions, and methods for solving the Navier-Stokes equations. The 31 papers presented at the meeting are published in AGARD Conference Proceedings CP-412 and are listed in the Appendix of this report. A brief synopsis of each paper and some general conclusions and recommendations are given.

Mccroskey, W. J.↗

VSAERO analysis of structurally decoupled tip planforms for a semispan wing

A numerical analysis has been conducted with the three-dimensional panel code VSAERO for two interacting lifting surfaces that are separated in the spanwise direction by a narrow gap, with the angle of attack of the outboard section being set independently of the inboard section, as in the 'free tip' rotor blade system proposed for helicopters. Computed values of tip surface lift and pitching moment coefficients are correlated with experimental data to determine the most suitable method for modeling the gap region between the surfaces. It is shown that the induced drag of the tip surface is reduced for negative incidence angles relative to the inboard section.

Martin, Daniel M.↗

SCBUCKLE user's manual: Buckling analysis program for simple supported and clamped panels

The program SCBUCKLE calculates the buckling loads and mode shapes of cylindrically curved, rectangular panels. The panel is assumed to have no imperfections. SCBUCKLE is capable of analyzing specially orthotropic symmetric panels (i.e., A(sub 16) = A(sub 26) = 0.0, D(sub 16) = D(sub 26) = 0.0, B(sub ij) = 0.0). The analysis includes first-order transverse shear theory and is capable of modeling sandwich panels. The analysis supports two types of boundary conditions: either simply supported or clamped on all four edges. The panel can be subjected to linearly varying normal loads N(sub x) and N(sub y) in addition to a constant shear load N(sub xy). The applied loads can be divided into two parts: a preload component; and a variable (eigenvalue-dependent) component. The analysis is based on the modified Donnell's equations for shallow shells. The governing equations are solved by Galerkin's method.

Cruz, Juan R.↗

Thermographic Qualification of Graphite/Epoxy Instrumentation Racks

A nondestructive evaluation method is desired for ensuring the 'as manufactured' and 'post service' quality of graphite/epoxy instrumentation rack shells. The damage tolerance and geometry of the racks dictate that the evaluation method be capable of identifying defects, as small as 0.25 inch 2 in area, over large acreage regions, tight compound radii and thickness transition zones. The primary defects of interest include voids, inclusions, delaminations and porosity. The potential for an infrared thermographic inspection to replace ultrasonic testing, for qualifying the racks as 'defect free' is under investigation. The inspection process is validated by evaluating defect standard panels built to the same specifications as the racks, except for the insertion of artificial fabricated defects. The artificial defects are designed to match those which are most prevalent in the actual instrumentation racks. A target defect area of 0.0625 inch 2 (a square with 0.25 inch on a side) was chosen for the defect standard panels to ensure the ability to find all defects of the critical (0.25 inch squared) size.

Walker, James L.↗

Techniques and Tools of NASA's Space Shuttle Columbia Accident Investigation

The Space Shuttle Columbia accident investigation was a fusion of many disciplines into a single effort. From the recovery and reconstruction of the debris, Figure 1, to the analysis, both destructive and nondestructive, of chemical and metallurgical samples, Figure 2, a multitude of analytical techniques and tools were employed. Destructive and non-destructive testing were utilized in tandem to determine if a breach in the left wing of the Orbiter had occurred, and if so, the path of the resultant high temperature plasma flow. Nondestructive analysis included topometric scanning, laser mapping, and real-time radiography. These techniques were useful in constructing a three dimensional virtual representation of the reconstruction project, specifically the left wing leading edge reinforced carbon/carbon heat protectant panels. Similarly, they were beneficial in determining where sampling should be performed on the debris. Analytic testing included such techniques as Energy Dispersive Electron Microprobe Analysis (EMPA), Electron Spectroscopy Chemical Analysis (ESCA), and X-Ray dot mapping; these techniques related the characteristics of intermetallics deposited on the leading edge of the left wing adjacent to the location of a suspected plasma breach during reentry. The methods and results of the various analyses, along with their implications into the accident, are discussed, along with the findings and recommendations of the Columbia Accident Investigation Board. Likewise, NASA's Return To Flight efforts are highlighted.

McDanels, Steve J.↗

Origins of Line Defects in Self-Reacting Friction Stir Welds and Their Impact on Weld Quality

Friction stir welding (FSWing) is a solid state joining technique which reduces the occurrence of typical defects formed in fusion welds, especially of highly alloyed metals. Although the process is robust for aluminum alloys, occasional reductions in the strength of FSWs have been observed. Shortly after the NASA-MSFC implemented a variation of FSW called self-reacting (SR), low strength properties were observed. At that time, this reduction in strength was attributed to a line defect. At that time, the limited data suggested that the line defect was related to the accumulation of native oxides that form on the weld lands and faying surfaces. Through a series of improved cleaning methods, tool redesign, and process parameter modifications, the reduction in the strength of the SR-FSWs was eliminated. As more data has been collected, the occasional reduction in the strength of SR-FSW still occurs. These occasional reductions indicate a need to reexamine the underlying causes. This study builds off a series of self reacting (SR)-FSWs that were made in 3 different thickness panels of AA2219 (0.95, 1.27 and 1.56 cm) at 2 different weld pitches. A bead on plate SR-FSW was also made in the 1.56 cm thick panel to understand the contribution of the former faying surfaces. Copper tracer studies were used to understand the flow lines associated with the weld tool used. The quality of the SR-FSWs was evaluated from tensile testing at room temperature. Reductions in the tensile strength were observed in some weldments, primarily at higher weld pitch or tool rotations. This study explores possible correlations between line defects and the reduction of strength in SR-FSWs. Results from this study will assist in a better understand of the mechanisms responsible for reduced tensile strength and provide methodology for minimizing their occurrence.

Schneider, Judy↗

Technology of civil usage of composites

The paper deals with the use of advanced composites in structural components of commercial aircraft. The need for testing the response of a material system to service environment is discussed along with methods for evaluating design and manufacturing aspects of a built-up structure under environmental conditions and fail-safe (damage-tolerance) evaluation of structures. Crashworthiness aspects, the fire-hazard potential, and electrical damage of composite structures are considered. Practical operational experience with commercial aircraft is reviewed for boron/epoxy foreflaps, Kevlar/epoxy fillets and fairings, graphite/epoxy spoilers, graphite/polysulfone spoilers, graphite/epoxy floor posts, boron/aluminum aft pylon skin panels, graphite/epoxy engine nose cowl outer barrels, and graphite/epoxy upper aft rudder segments.

Kemp, D. E.↗