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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

Summary of Activities for Health Monitoring of Composite Overwrapped Pressure Vessels

This three-year project (FY12-14) will design and demonstrate the ability of new Magnetic Stress Gages for the measurement of stresses on the inner diameter of a Composite Overwrapped Pressure Vessel overwrap. The sensors are being tested at White Sands Testing Facility (WSTF) where the results will be correlated with a known nondestructive technique acoustic emission. The gages will be produced utilizing Meandering Winding Magnetometer (MWM) and/or MWM array eddy current technology. The ultimate goal is to utilize this technology for the health monitoring of Composite Overwrapped Pressure Vessels for all future flight programs. The first full-scale pressurization test was performed at WSTF in June 2012. The goals of this test were to determine adaptations of the magnetic stress gauge instrumentation that would be necessary to allow multiple sensors to monitor the vessel's condition simultaneously and to determine how the sensor response changes with sensor selection and orientation. The second full scale pressurization test was performed at WSTF in August 2012. The goals of this test were to monitor the vessel's condition with multiple sensors simultaneously, to determine the viability of the multiplexing units (MUX) for the application, and to determine if the sensor responses in different orientations are repeatable. For both sets of tests the vessel was pressured up to 6,000 psi to simulate maximum operating pressure. Acoustic events were observed during the first pressurization cycle. This suggested that the extended storage period prior to use of this bottle led to a relaxation of the residual stresses imparted during auto-frettage. The pressurization tests successfully demonstrated the use of multiplexers with multiple MWM arrays to monitor a vessel. It was discovered that depending upon the sensor orientation, the frequencies, and the sense element, the MWM arrays can provide a variety of complementary information about the composite overwrapped pressure vessel load conditions. For example, low frequency measurements can be used to monitor the overwrap thickness and changes associated with pressure level. High frequency data is dominated by the properties of the overwrap, including the fiber orientations and lay-up of the layers.

Russell, Rick↗
NASA NTRS2005

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.↗
NASA NTRS2010

Nondestructive Evaluation and Monitoring Results from COPV Accelerated Stress Rupture Testing, NASA White Sands Test Facility (WSTF)

Develop and demonstrate NDE techniques for real-time characterization of CPVs and, where possible, identification of NDE capable of assessing stress rupture related strength degradation and/or making vessel life predictions (structural health monitoring or periodic inspection modes). Secondary: Provide the COPV user and materials community with quality carbon/epoxy (C/Ep) COPV stress rupture progression rate data. Aid in modeling, manufacturing, and application of COPVs for NASA spacecraft.

Saulsberry Regor↗
DOE OSTI2024

Long-Term Performance of Ag/AgCl Reference Electrodes for Corrosion Potential Monitoring in Radioactive Tank Waste at the Hanford Site

This work studied the exposure effects of radioactive tank waste on the long-term performance of single junction Ag/AgCl reference electrodes for corrosion potential monitoring at the Hanford Site. Electrodes from three manufacturers with very different designs were studied using open-circuit potential and electrochemical impedance measurements in radioactive tank waste. Post-test analyses were conducted on some failed electrodes using destructive and nondestructive techniques. The intrusion of the aggressive and radioactive chemicals in tank waste through the porous frit materials was the primary mechanism that led to the clogging of frit, physical and chemical degradation of AgCl bonded to Ag wire, and alteration of the internal electrolyte. Radiolytic chemical species such as H2O2 and HNO3 may have also induced the degradation of the Ag wire. The extent of electrode degradation and failure probability highly depended on the electrode design and environmental conditions. Chemicals in tank waste had stronger effects than radiation on the long-term performance of the Ag/AgCl reference electrodes.

Materials Science↗
NASA NTRS1972

Nondestructive testing of Scout rocket motors

The nondestructive tests applied to Scout rocket motors were reviewed and appraised. Analytical techniques were developed to evaluate the capabilities of the radiographic and ultrasonic procedures used. Major problem areas found were the inadequacy of high voltage radiography for detecting unbonds and propellant cracks having narrow widths, the inability to relate the ultrasonic signals received from flat-bottomed holes in standards to those received from real defects and in the general area of the specification of acceptance criteria and how these were to be met. To counter the deficiencies noted, analyses were conducted to the potential utility of radiometric, acoustic, holographic and thermographic techniques for motor and nozzle bond inspection, a new approach to qualifying magnetic particle inspection and the application of acoustic emission analysis to the evaluation of proof and leak test data.

Oaks, A. E.↗
NASA NTRS1988

RF Testing Of Microwave Integrated Circuits

Fixtures and techniques are undergoing development. Four test fixtures and two advanced techniques developed in continuing efforts to improve RF characterization of MMIC's. Finline/waveguide test fixture developed to test submodules of 30-GHz monolithic receiver. Universal commercially-manufactured coaxial test fixture modified to enable characterization of various microwave solid-state devices in frequency range of 26.5 to 40 GHz. Probe/waveguide fixture is compact, simple, and designed for non destructive testing of large number of MMIC's. Nondestructive-testing fixture includes cosine-tapered ridge, to match impedance wavequide to microstrip. Advanced technique is microwave-wafer probing. Second advanced technique is electro-optical sampling.

Romanofsky, R. R.↗
NASA NTRS1998

Damage Detection and Impact Testing on Laminated and Sandwich Composite Panels

This research investigates health monitoring of sandwich shell composites to determine if the Transmittance Functions (TF) are effective in determining the present of damage. The health monitoring test was conducted on the sandwich plates before and after low velocity impacts using the health monitoring technique given in TFs are a NDE (Nondestructive Evaluation) technique that utilizes the ratios of cross-spectrums to auto-spectrums between two response points on the sandwich composites. The test for transmittance was conducted on the same density foam core throughout the experiment. The test specimens were 17.8 cm by 25.4 cm in dimension. The external sheets (face sheets) were created from graphite/epoxy laminate with dimension of 1.58 mm thick. The polymethacrylide (Rohacell) foam core was 12.7 mm thick. These samples experienced a transformation in the TF that was considered the low velocity impact damage. The low velocity damage was observed in the TFs for the sandwich composites.

Hughes, Derke R.↗
NASA NTRS1979

Rapid data comparison technique development for N-ray/X-ray analysis

An operational N-ray/X-ray computer analysis system for nondestructive testing problems was realized by developing: (1) more efficient data transfer routines for use in existing image processing systems; (2) the capability to store and analyze multiple N-ray/X-ray images; (3) an efficient 2-D Fast Fourier Transform; and (4) transfer functions compensation capability to correct for distortions and nonlinearities of N-rays/X-rays. Applications of the technique are summarized for the following: thermal protection system tile with hydraulic fluid; thermal protection system tile with corrosion; thermal protection system tile debonding; stainless steel tubing corrosion; defective electrical devices; fast film restoration and deblur; corrosion tracking over time; reduction of source vignetting, and identification of materials (0 rings, Teflon parts, soft goods) via table look up.

Butterfield, R. L.↗
DOE OSTI2018

Application of IR Thermography with Thermal Diffusivity Analysis for Detection of Plies Displacement in CFRP Composites

This paper presents an efficient nondestructive testing (NDT) method for detection of plies displacement in carbon fiber reinforced plastic (CFRP) composites using the active thermography technique. To assess the capability of the proposed technique for detection of plies displacement, the CFRP composite specimens with simulated fault were designed and manufactured. The IR thermography measurements were conducted using two-sided experimental arrangement. From recorded sequences of thermal images, the temperature variations versus time plots were extracted to obtain the maximum thermal contrasts. For quantitative interpretation of the results, the thermal diffusivity values for each composite material were determined and related to the fiber volume fraction. The experimental results showed that the thermal diffusivity increases with an increase of fiber volume fraction; further, the values of thermal diffusivity are specimen thickness dependent. The obtained values of thermal diffusivity varied from 1.5 × 10{sup −7} m{sup 2}/s (for 3.2 mm composite with 8.5 vol.% carbon fiber) to 2.6 × 10{sup −7} m{sup 2}/s (for 7.7 mm composite with 34.1 vol.% carbon fiber). On the basis of these results, it was concluded that the active thermography combined with thermal diffusivity analysis can be considered as a reliable NDT technique for detection of plies displacement in CFRP composites.

36 MATERIALS SCIENCE↗
DOE OSTI2023

An Assessment of Machine Learning Applied to Ultrasonic Nondestructive Evaluation

In the United States, the nuclear industry performs inservice inspection (ISI) through nondestructive examination (NDE) methods in accordance with guidelines specified in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section XI, Rules for Inservice Inspection of Nuclear Power Plant Components. Ultrasonic nondestructive testing and evaluation (NDT&E) is one of the more commonly used techniques for inspecting Class 1 structural components in nuclear power systems. As the number of qualified NDE inspectors declines, the nuclear industry is looking to take advantage of advances in automation to enhance inspection capabilities. Advances in computational power, cloud-based computing, and machine learning algorithms make automated data analysis possible. Machine learning (ML) has shown huge potential in automated data analyses for ultrasonic NDE in the context of weld inspections.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1974

Nondestructive testing of railroad wheels and rails by ultrasonics

Quality control of wheels and rails can be improved by using ultrasonic technique developed for measuring stresses in metallic materials. In addition, parts already in use can be tested and replaced if they are found to be unsafe. Test equipment includes two transducers.

Clotfelter, W. M.↗
NASA NTRS1975

Testing of printed circuit board solder joints by optical correlation

An optical correlation technique for the nondestructive evaluation of printed circuit board solder joints was evaluated. Reliable indications of induced stress levels in solder joint lead wires are achievable. Definite relations between the inherent strength of a solder joint, with its associated ability to survive stress, are demonstrable.

Espy, P. N.↗
NASA NTRS1977

Composite pressure vessels for the Space Shuttle Orbiter

During the development of the Space Shuttle Orbiter propulsion and environmental control subsystems it was recognized that use of composite pressure vessels with load sharing liners could provide significant weight savings for high pressure gas containment. A program is described which was undertaken to assess the utility for orbiter applications of titanium 6Al-4V and Inconel 718 liners overwrapped with Kevlar fibers. Vessel characteristics, design features and test results are presented along with brief descriptions of processes and nondestructive evaluation techniques. The resolutions of anomalies and development of design are also presented. Fracture control as applied to the orbiter composite vessels is briefly discussed. Five of the seven titanium lined vessels in the program experienced premature cyclic failures. These failures were shown to be primarily due to metallurgical anomalies rather than an inherent composite design problem. A nonfragmentary leakage mode of failure was demonstrated at operating pressures. The composite designs will be approximately 25 percent lighter than their all metal counterparts.

Ecord, G. M.↗
NASA NTRS2007

Interrelationship of Nondestructive Evaluation Methodologies Applied to Testing of Composite Overwrapped Pressure Vessels

Composite Overwrapped Pressure Vessels (COPVs) are commonly used in spacecraft for containment of pressurized gases and fluids, incorporating strength and weight savings. The energy stored is capable of extensive spacecraft damage and personal injury in the event of sudden failure. These apparently simple structures, composed of a metallic media impermeable liner and fiber/resin composite overwrap are really complex structures with numerous material and structural phenomena interacting during pressurized use which requires multiple, interrelated monitoring methodologies to monitor and understand subtle changes critical to safe use. Testing of COPVs at NASA Johnson Space Center White Sands T est Facility (WSTF) has employed multiple in-situ, real-time nondestructive evaluation (NDE) methodologies as well as pre- and post-test comparative techniques to monitor changes in material and structural parameters during advanced pressurized testing. The use of NDE methodologies and their relationship to monitoring changes is discussed based on testing of real-world spacecraft COPVs. Lessons learned are used to present recommendations for use in testing, as well as a discussion of potential applications to vessel health monitoring in future applications.

Leifeste, Mark R.↗
NASA NTRS2010

Nondestructive Evaluation Methods for the Ares I Common Bulkhead

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

Walker, James↗
NASA NTRS1976

Detection of tightly closed flaws by nondestructive testing (NDT) methods in steel and titanium

X-radiographic, liquid penetrant, ultrasonic, eddy current and magnetic particle testing techniques were optimized and applied to the evaluation of 4340 steel (180 KSI-UTS) and 6Al-4V titanium (STA) alloy specimens. Sixty steel specimens containing a total of 176 fatigue cracks and 60 titanium specimens containing a total of 135 fatigue cracks were evaluated. The cracks ranged in length from .043 cm (0.017 inch) to 1.02 cm (.400 inch) and in depth from .005 cm (.002 inch) to .239 cm (.094 inch) for steel specimens. Lengths ranged from .048 cm (0.019 inch) to 1.03 cm (.407 inch) and depths from 0.010 cm (.004 inch) to .261 cm (0.103 inch) for titanium specimens. Specimen thicknesses were nominally .152 cm (0.060 inch) and 0.635 cm (0.250 inch) and surface finishes were nominally 125 rms. Specimens were evaluated in the "as machined" surface condition, after etch surface and after proof loading in a randomized inspection sequence.

Rummel, W. D.↗