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At least 19 records

IR Thermography NDE of ISS Radiator Panels

The presentation covers an active and a passive infrared (IR) thermography for detection of delaminations in the radiator panels used for the International Space Station (ISS) program. The passive radiator IR data was taken by a NASA astronaut in an extravehicular activity (EVA) using a modified FLIR EVA hand-held camera. The IR data could be successfully analyzed to detect gross facesheet disbonds. The technique used the internal hot fluid tube as the heat source in analyzing the IR data. Some non-flight ISS radiators were inspected using an active technique of IR flash thermography to detect disbond of face sheet with honeycomb core, and debonds in facesheet overlap areas. The surface temperature and radiated heat emission from flight radiators is stable during acquisition of the IR video data. This data was analyzed to detect locations of unexpected surface temperature gradients. The flash thermography data was analyzed using derivative analysis and contrast evolutions. Results of the inspection are provided.

Koshti, Ajay↗

IR Thermography of International Space Station Radiator Panels

Several non-flight qualification test radiators were inspected using flash thermography. Flash thermography data analysis used raw and second derivative images to detect anomalies (Echotherm and Mosaic). Simple contrast evolutions were plotted for the detected anomalies to help in anomaly characterization. Many out-of-family indications were noted. Some out-of-family indications were classified as cold spot indications and are due to additional adhesive or adhesive layer behind the facesheet. Some out-of-family indications were classified as hot spot indications and are due to void, unbond or lack of adhesive behind the facesheet. The IR inspection helped in assessing expected manufacturing quality of the radiators.

Koshti, Ajay↗

Implementing Recommendations of the Columbia Accident Investigation Board: Development of On-Orbit IR Thermography

One of NASA's Space Shuttle Return-to-Flight (RTF) efforts has been to develop thermography for the on-orbit inspection of the Reinforced Carbon Carbon (RCC) portion of the Orbiter Wing Leading Edge (WLE). This paper addresses the capability of thermography to detect cracks in RCC by using in-plane thermal gradients that naturally occur on-orbit. Crack damage, which can result from launch debris impact, is a detection challenge for other on-orbit sensors under consideration for RTF, such as the Intensified Television Camera and Laser Dynamic Range Imager. We studied various cracks in RCC, both natural and simulated, along with material characteristics, such as emissivity uniformity, in steady-state thermography. Severity of crack, such as those likely and unlikely to cause burn through were tested, both in-air and in-vacuum, and the goal of this procedure was to assure crew and vehicle safety during reentry by identification and quantification of a damage condition while on-orbit. Expected thermal conditions are presented in typical shuttle orbits, and the expected damage signatures for each scenario are presented. Finally, through statistical signal detection, our results show that even at very low in-plane thermal gradients, we are able to detect damage at or below the threshold for fatality in the most critical sections of the WLE, with a confidence exceeding 1 in 10,000 probability of false negative.

Ottens, Brian P.↗

Shockwave/Boundary-Layer Interaction Studies Performed in the NASA Langley 20-Inch Mach 6 Air Tunnel

This paper highlights results from a collaborative study performed by The University of Tennessee Space Institute (UTSI) and NASA Langley Research Center on the Shockwave/Boundary-Layer Interaction (SWBLI) generated by a cylindrical protuberance on a flat plate in a Mach 6 flow. The study was performed in the 20-Inch Mach 6 Air Tunnel at NASA Langley Research Center and consisted of two separate entries. In the first entry, simultaneous high-speed schlieren and high-speed pressure-sensitive paint (PSP) imaging – which was performed for the first time in the 20-Inch Mach 6 facility at NASA Langley – were performed as well as simultaneous high-speed schlieren and oil-flow imaging. In the second entry, the model configuration was modified to increase the size of the interaction region. High-speed schlieren and infrared thermography (IR) surface imaging were performed in this second entry. The goal of these tests was to characterize the SBLI in the presence of a laminar, transitional, and turbulent boundary layer using high-speed optical imaging techniques. AoA = sting angle-of-attack (°) dcylinder = cylinder diameter (mm) dtrip = cylindrical tripping element diameter (mm) Δshock = shock stand-off distance (mm) hcylinder = cylinder height (mm) htrip = cylindrical tripping element height (mm) HSS = high-speed schlieren M∞ = freestream Mach number PSP = pressure-sensitive paint Re∞ = freestream unit Reynolds number (m-1) SWBLI = shockwave/boundary-layer interaction θplate = model plate angle (°) Introduction his paper highlights two experimental entries performed in the 20-Inch Mach 6 Air Blowdown Tunnel at NASA Langley Research Center in collaboration with The University of Tennessee Space Institute (UTSI). The purpose of these entries was to characterize the dynamic shockwave/boundary-layer interaction (SWBLI) between a vertical cylinder on a flat plate and laminar, transitional (XSWBLI), and turbulent (SWTBLI) boundary layers with a freestream Mach number of 6 using non-intrusive optical diagnostics. Experiments performed by Murphree et al.1,2 were among the first to specifically characterize XSWBLI induced by a vertical cylinder on a flat plate geometry using several optical measurement techniques. Recent optical studies of XSWBLI phenomenon have been performed by UTSI at Mach 2 in their low-enthalpy blow wind tunnel3-8 and by Texas A&M University and UTSI at Mach numbers of 6 and 7 in their Adjustable Contour Expansion wind tunnel.9 The experiments described in this paper were intended to complement previous studies by expanding the freestream unit Reynolds number range, Re∞, over which the XSWBLI phenomena has been observed. Additionally these experiments, made possible under NASA’s new facility funding model under the Aeronautics Evaluation and Test Capabilities (AETC) project, promoted collaboration between university and NASA researchers. The initial entry in the 20-Inch Mach 6 Air Tunnel at NASA Langley occurred in December of 2016. Originally, testing was to occur in November of 2016 in the 31-Inch Mach 10 Air Tunnel at NASA Langley. This facility was chosen so that the XSWBLI phenomenon could be observed at much higher Mach numbers than had previously been attempted in ground test experiments. The model selected for this experiment, a 10° half-angle wedge with a sharp leading edge (described in detail in section II.B), had previously been used by Danehy et al. [10] for boundary layer transition studies using the nitric oxide planar laser-induced fluorescence (NO PLIF) flow visualization technique. In that work, it was determined that transition could be induced downstream of a single htrip = 1-mm tall, dtrip = 4-mm diameter cylindrical tripping element and that the streamwise location of the transition could be changed for a single Re∞ by changing the model angle-of-attack (AoA) (see Fig. A3 in Ref. [10] for more details). Based on the findings of that work, a decision was made to use the wedge model with the cylindrical tripping element to trip the boundary layer flow ahead of a cylindrical protuberance in order to achieve a XSWBLI. Unfortunately, the 31-Inch Mach 10 facility had been taken offline for repairs in October of 2016 and a decision was made to move the test to the 20-Inch Mach 6 facility. Since the behavior of the boundary layer with the chosen model configuration had not been studied before in that facility and the available test time was limited, the entry was considered to be exploratory and was used to collect spatially-resolved and time-resolved flow and surface visualization data that would be used to inform a second entry. Test techniques included simultaneous high-speed schlieren (HSS) captured at 160 kHz and high-speed pressure sensitive paint captured at 10 kHz as well as oil flow visualization, captured at 750 Hz. The second entry in the 20-Inch Mach 6 facility occurred in June and July of 2017. In this follow-on test, modifications to the wind tunnel model were made based on observations made during the first entry and included removing the cylindrical tripping element, increasing the size of the cylinder used to induce the SWBLI to increase the size of the interaction while simultaneously improving spatial resolution, and using a swept ramp array, similar to that described in Ref. [11], to trip the flow to turbulence. Simultaneous HSS (captured at 140 kHz, 100 kHz, and 40 kHz) and conventional IR thermography (captured at 30 Hz) imaging were performed simultaneously in this follow-on entry. This paper is intended to serve as a summary of the work performed during these two entries, to detail lessons learned from each entry, and to highlight some of the datasets acquired. Details on the experimental setup, model configuration, and techniques used are provided. Papers providing a more rigorous analysis of data acquired during the second entry, including statistical, spectral, and modal decomposition methods, can be found in Refs. [12,13]. An entry examining XSWBLI in the 31-Inch Mach 10 Blowdown Wind Tunnel facility is currently planned for mid-to-late calendar year 2019, pending the success of facility repairs. The work performed and described in this paper and the upcoming entry in the 31-Inch Mach 10 facility at NASA Langley have been made possible by NASA’s new facility funding model under the Aeronautics Evaluation and Test Capabilities (AETC) project. Wind Tunnel Facility All experiments discussed in this paper were performed in the 20-Inch Mach 6 Air Tunnel at NASA Langley Research Center. Specific details pertaining to this facility can be found in Refs. [14,15], with only a brief description of the facility provided here. For both entries, the nominal freestream unit Reynolds number was varied between 1.8×106 m-1 (0.5×106 ft-1) and 26.3×106 m-1 (8×106 ft-1). The nominal stagnation pressure was varied between 0.21 MPa and 3.33 MPa and the nominal stagnation temperature was varied between 480 K and 520 K to achieve the desired Re∞ condition. For all runs, the nominal freestream Mach number was 6. The nearly square test section is 520.7-mm (20.5-inches) wide by 508-mm (20-inches) high. Two 431.8-mm (17-inch) diameter windows made of Corning 7940, Grade 5F schlieren-quality glass serve as the side walls of the tunnel and provide optical access for the high-speed schlieren measurements. A rectangular window made of the same material as the side windows served as the top wall of the test section and provided optical access for the high-speed PSP and oil flow measurements. For the second entry, this top window was replaced with a Zinc Selenide (ZnSe) window with an anti-reflection coating capable of passing IR wavelengths between 8μm and 12μm with greater than 98% transmittance. The model was sting supported by a strut attached to a hydraulic system that allows for the model pitch angle to be adjusted between -5° to +55°. For the first entry, an initial pitch/pause sweep of the model AoA was performed to observe the resulting SWBLI. Ultimately, however, the sting pitch angle for this entry was fixed at +10.0° so that the angle of the top surface of the wedge relative to the streamwise axis of the tunnel (referred to herein as the plate angle, θplate), was θplate = 0°. For the second entry, θplate = 0° and θplate = -13.25° were initially tested with the swept ramp array (discussed in the following section) to determine which orientation produced conditions most favorable for XSWBLI to occur based on the heating signatures observed over the top surface of the model in the IR thermography images. Based on these initial tests, θplate = -13.25° was set for the remainder of the runs in the second entry. For both entries, any model changes were performed in a housing located beneath the closed test section. Prior to performing a run of the tunnel, the housing was sealed and the tunnel started. Once the appropriate freestream conditions were achieved, the model was injected into the test section using a hydraulic injection system. B. Model Geometry For all runs, a 10° half-angle (20° full-angle) wedge model with a sharp leading edge was used. The model is described in detail in Refs. [10,16]. The top surface of the sharp leading edge of the model extended 47.8 mm from its upstream-most edge to a junction with the upstream edge of a stainless steel top plate that then extended an (a) (c) (b) Fig. 1 (a) Schematic of top surface of wedge model with gas seeding insert, (b) perspective view of the model in the 20-Inch Mach 6 tunnel with centerline pressure orifices on sharp leading edge, and (c) a perspective view of the model with stainless steel (top) and SLA middle insert (bottom) during the first entry. Flow occurs from left to right.

Bathel, Brett F.↗

Hypersonic Fluid-Thermal-Structural Interactions on a Compression Ramp with an Embedded Compliant Panel

The fluid-thermal-structural interactions of a compliant panel embedded in a compression ramp are explored experimentally at Mach 6. The panel structural response is investigated for turbulent and transitional shock-wave/boundary-layer interactions at five distinct interaction strengths and up to four different pressure differentials. Upstream of the compression corner, fast-response piezoresistive pressure transducers show the feedback of the panel vibrations and static deflection on the upstream pressure fluctuations. The magnitude of the pressure fluctuation rms shows a reduction in the upstream disturbances when a pressure differential is applied across the compliant panel. Photogrammetry and IR thermography are used simultaneously to measure the panel deformations and surface temperature. Panel deformation, frequency shifting, and frequency bifurcation are consistent with post-thermal-buckling behavior.

hypersonic↗

Flight Tests of a Supersonic Natural Laminar Flow Airfoil

IR thermography was used to characterize the transition front on a S-NLF test article at chord Reynolds numbers in excess of 30 million Changes in transition due to Mach number, Reynolds number, and surface roughness were investigated - Regions of laminar flow in excess of 80% chord at chord Reynolds numbers greater than 14 million IR thermography clearly showed the transition front and other flow features such as shock waves impinging upon the surface A series of parallel oblique shocks, of yet unknown origin, were found to cause premature transition at higher Reynolds numbers. NASA has a current goal to eliminate barriers to the development of practical supersonic transport aircraft Drag reduction through the use of supersonic natural laminar flow (S-NLF) is currently being explored as a means of increasing aerodynamic efficiency - Tradeoffs work best for business jet class at M<2 Conventional high-speed designs minimize inviscid drag at the expense of viscous drag - Existence of strong spanwise pressure gradient leads to crossflow (CF) while adverse chordwise pressure gradients amplifies and Tollmien-Schlichting (TS) instabilities Aerion Corporation has patented a S-NLF wing design (US Patent No. 5322242) - Low sweep to control CF - dp/dx < 0 on both wing surfaces to stabilize TS - Thin wing with sharp leading edge to minimize wave drag increase due to reduction in sweep NASA and Aerion have partnered to study S-NLF since 1999 Series of S-NLF experiments flown on the NASA F-15B research test bed airplane Infrared (IR) thermography used to characterize transition - Non-intrusive, global, good spatial resolution - Captures significant flow features well

laminar flow↗

Effects of moisture in infrared thermography of resin matrix composites

Several multiply graphite polyimide composite specimens were examined by real-time infrared thermography in order to study the effects of moisture on their thermograms. Heat was injected from one side and IR emission detected on the opposite side using AGA Thermovision System-680. No differences between the thermograms of dry and water containing specimens were detected for defect-free specimens. However, the presence of trapped water in defective specimens modified the thermographic contrast significantly. It is concluded that: (1) IR thermography can be used to detect moisture in defective composites, and (2) because of the possibility of moisture camouflaging defects, IR thermography for subsurface defect detection should be supplemented by other techniques - such as acoustical imaging and X-radiography.

Singh, J. J.↗

Boundary-Layer Detection at Cryogenic Conditions Using Temperature Sensitive Paint Coupled with a Carbon Nanotube Heating Layer

Detection of flow transition on aircraft surfaces and models can be vital to the development of future vehicles and computational methods for evaluating vehicle concepts. In testing at ambient conditions, IR thermography is ideal for this measurement. However, for higher Reynolds number testing, cryogenic facilities are often used, in which IR thermography is difficult to employ. In these facilities, temperature sensitive paint is an alternative with a temperature step introduced to enhance the natural temperature change from transition. Traditional methods for inducing the temperature step by changing the liquid nitrogen injection rate often change the tunnel conditions. Recent work has shown that adding a layer consisting of carbon nanotubes to the surface can be used to impart a temperature step on the model surface with little change in the operating conditions. Unfortunately, this system physically degraded at 130 K and lost heating capability. This paper describes a modification of this technique enabling operation down to at least 77 K, well below the temperature reached in cryogenic facilities. This is possible because the CNT layer is in a polyurethane binder. This was tested on a Natural Laminar Flow model in a cryogenic facility and transition detection was successfully visualized at conditions from 200 K to 110 K. Results were also compared with the traditional temperature step method.

Goodman, Kyle Z.↗

Desirable features of an infrared imaging system for aerodynamic research

Advantage of non-intrusiveness, capability for field measurement, and increased availability of IR imaging systems have resulted in their wider use for aerodynamic research. However, certain difficulties persist while using currently available systems for such applications. A critical evaluation of the IR imaging systems is presented on the basis of the state-of-the-art of IR imaging technology and experiences in wind tunnel and flight testing at NASA's Langley Research Center. The requirements for using IR thermography as a measurement tool in aerodynamic research are examined in terms of range, sensitivity, and accuracy of temperature measurement, temporal and spatial resolution, and features of target. Deficiencies of present IR imaging systems are identified, and user precautions to avoid such problems by proper selection and operation of these units are suggested. Different aspects of imager performance such as imager optics, video capabilities, and environmental tolerance are discussed. Electronic data recording and image processing hardware and software requirements are evaluated. Slit response tests and spatial resolution are discussed with the objective of obtaining reliable, accurate, and meaningful information from IR thermography measurements for aerodynamic studies.

Wright, Robert E., Jr.↗

Development of an Extra-vehicular (EVA) Infrared (IR) Camera Inspection System

Designed to fulfill a critical inspection need for the Space Shuttle Program, the EVA IR Camera System can detect crack and subsurface defects in the Reinforced Carbon-Carbon (RCC) sections of the Space Shuttle s Thermal Protection System (TPS). The EVA IR Camera performs this detection by taking advantage of the natural thermal gradients induced in the RCC by solar flux and thermal emission from the Earth. This instrument is a compact, low-mass, low-power solution (1.2cm3, 1.5kg, 5.0W) for TPS inspection that exceeds existing requirements for feature detection. Taking advantage of ground-based IR thermography techniques, the EVA IR Camera System provides the Space Shuttle program with a solution that can be accommodated by the existing inspection system. The EVA IR Camera System augments the visible and laser inspection systems and finds cracks and subsurface damage that is not measurable by the other sensors, and thus fills a critical gap in the Space Shuttle s inspection needs. This paper discusses the on-orbit RCC inspection measurement concept and requirements, and then presents a detailed description of the EVA IR Camera System design.

Gazarik, Michael↗

Aftbody Aeroheating Wind Tunnel Measurements on a Hypersonic Inflatable Aerodynamic Decelerator

The aftbody aeroheating environment of a Hypersonic Inflatable Aerodynamic Decelerator (HIAD) was investigated in the NASA Langley 31-Inch Mach 10 Air Tunnel. The wind tunnel model geometry was representative of the Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) vehicle. Aeroheating data were obtained for a range of Reynolds numbers and angles-of-attack using global phosphor thermography. Aeroheating data were also obtained using a developmental IR thermography technique for evaluation of data quality.

Elizabeth F Rieken↗

Study of optical techniques for the Ames unitary wind tunnel. Part 5: Infrared imagery

A survey of infrared thermography for aerodynamics was made. Particular attention was paid to boundary layer transition detection. IR thermography flow visualization of 2-D and 3-D separation was surveyed. Heat transfer measurements and surface temperature measurements were also covered. Comparisons of several commercial IR cameras were made. The use of a recently purchased IR camera in the Ames Unitary Plan Wind Tunnels was studied. Optical access for these facilities and the methods to scan typical models was investigated.

Lee, George↗

Defect Characterization in a Thin Walled Composite RP-1 Tank: A Case Study

A full scale thin walled composite tank, designed and fabricated for the storage of pressurized RP- I rocket fuel, was fully inspected with digital infrared thermography (IR) during assembly and prior to proof testing. The tank featured a "pill capsule" design with the equatorial bondline being overwrapped on both the inner and outer surfaces. A composite skirt was bonded to the aft dome of the tank to serve as a structural support when the tank was stood on end in service. Numerous anomalies were detected and mapped prior to proof testing, some along bondlines and some scattered throughout the acreage. After the tank was intentionally burst, coupons were cut from the regions including thermographic anomalies. These coupons were again inspected thermographically to document the growth of any indications due to proof testing. Ultrasonic inspections (UT) were also performed on the coupons for comparison to thermography. Several coupons were dissected and micrographed. Relationships between IR and UT indications and the physical nature of the dissected material are presented.

Langsing, Matthew D.↗

Exit Presentation: Infrared Thermography on Graphite/Epoxy

This slide presentation reports on the internship project that was accomplished during the summer of 2010. The objectives of the project were to: (1) Simulate Flash Thermography on Graphite/Epoxy Flat Bottom hole Specimen and thin void specimens, (2) Obtain Flash Thermography data on Graphite/Epoxy flat bottom hole specimens, (3) Compare experimental results with simulation results, Compare Flat Bottom Hole Simulation with Thin Void Simulation to create a graph to determine size of IR Thermography detected defects

Comeaux, Kayla↗

Aerodynamic applications of infrared thermography

A series of wind tunnel experiments were conducted as part of a systematic study for evaluation of infrared thermography as a viable non-intrusive thermal measurement technique for aerodynamic applications. The experiments consisted of obtaining steady-state surface temperature and convective heat transfer rates for a uniformly heated cylinder in transverse flow with a Reynolds number range of 46,000 to 250,000. The calculated convective heat transfer rates were in general agreement with classical data. Furthermore, IR thermography provided valuable real-time fluid dynamic information such as visualization of flow separation, transition and vortices.

Daryabeigi, Kamran↗

The state of the art of conventional flow visualization techniques for wind tunnel testing

Conventional wind tunnel flow visualization techniques which consist of surface flow methods, tracers, and optical methods are presented. Different surface flow methods are outlined: (1) liquid films (oil and fluorescent dye and UV lighting, renewable film via porous dispenser in model, volatile carrier fluid, cryogenic colored oil dots, oil film interferometry); (2) reactive surface treatment (reactive gas injection, reversible dye); (3) transition and heat transfer detectors (evaporation, sublimation, liquid crystals, phase change paints, IR thermography); and (4) tufts (fluorescent mini tufts, cryogenic suitability). Other methods are smoke wire techniques, vapor screens, and optical methods.

Settles, G. S.↗

NASA programs in advanced sensors and measurement technology for aeronautical applications

NASA involvement in the development, implementation, and experimental use of advanced aeronautical sensors and measurement technologies is presently discussed within the framework of specific NASA research centers' activities. The technology thrusts are in the fields of high temperature strain gages and microphones, laser light-sheet flow visualization, LTA, LDV, and LDA, tunable laser-based aviation meteorology, and fiber-optic CARS measurements. IR thermography and close-range photogrammetry are undergoing substantial updating and application. It is expected that 'smart' sensors will be increasingly widely used, especially in conjunction with smart structures in aircraft and spacecraft.

Conway, Bruce A.↗

Design, Fabrication, and Testing of SMA Enabled Adaptive Chevrons for Jet Noise Reduction

This study presents the status and results from an effort to design, fabricate, and test an adaptive jet engine chevron concept based upon embedding shape memory alloy (SMA) actuators in a composite laminate, termed a SMA hybrid composite (SMAHC). The approach for fabricating the adaptive SMAHC chevrons involves embedding prestrained Nitinol actuators on one side of the mid-plane of the composite laminate such that thermal excitation generates a thermal moment and deflects the structure. A glass-epoxy pre-preg/Nitinol ribbon material system and a vacuum hot press consolidation approach are employed. A versatile test system for control and measurement of the chevron deflection performance is described. Projection moire interferometry (PMI) is used for global deformation measurement and infrared (IR) thermography is used for 2-D temperature measurement and feedback control. A recently commercialized constitutive model for SMA and SMAHC materials is used in the finite element code ABAQUS to perform nonlinear static analysis of the chevron prototypes. Excellent agreement is achieved between the predicted and measured chevron deflection performance, thereby validating the design tool. Although the performance results presented in this paper fall short of the requirement, the concept is proven and an approach for achieving the performance objectives is evident.

Turner, Travis L.↗