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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Challenges of NDE Simulation Tool Challenges of NDE Simulation Tool

Realistic nondestructive evaluation (NDE) simulation tools enable inspection optimization and predictions of inspectability for new aerospace materials and designs. NDE simulation tools may someday aid in the design and certification of advanced aerospace components; potentially shortening the time from material development to implementation by industry and government. Furthermore, modeling and simulation are expected to play a significant future role in validating the capabilities and limitations of guided wave based structural health monitoring (SHM) systems. The current state-of-the-art in ultrasonic NDE/SHM simulation cannot rapidly simulate damage detection techniques for large scale, complex geometry composite components/vehicles with realistic damage types. This paper discusses some of the challenges of model development and validation for composites, such as the level of realism and scale of simulation needed for NASA' applications. Ongoing model development work is described along with examples of model validation studies. The paper will also discuss examples of the use of simulation tools at NASA to develop new damage characterization methods, and associated challenges of validating those methods.

Leckey, Cara A. C.↗
NASA NTRS2016

Ultrasonic NDE Simulation for Composite Manufacturing Defects

The increased use of composites in aerospace components is expected to continue into the future. The large scale use of composites in aerospace necessitates the development of composite-appropriate nondestructive evaluation (NDE) methods to quantitatively characterize defects in as-manufactured parts and damage incurred during or post manufacturing. Ultrasonic techniques are one of the most common approaches for defect/damage detection in composite materials. One key technical challenge area included in NASA's Advanced Composite's Project is to develop optimized rapid inspection methods for composite materials. Common manufacturing defects in carbon fiber reinforced polymer (CFRP) composites include fiber waviness (in-plane and out-of-plane), porosity, and disbonds; among others. This paper is an overview of ongoing work to develop ultrasonic wavefield based methods for characterizing manufacturing waviness defects. The paper describes the development and implementation of a custom ultrasound simulation tool that is used to model ultrasonic wave interaction with in-plane fiber waviness (also known as marcelling). Wavefield data processing methods are applied to the simulation data to explore possible routes for quantitative defect characterization.

Leckey, Cara A. C.↗
NASA NTRSDate not supplied

Verification and Validation of Elastodynamic Simulation Software for Aerospace Research

Physics-based simulation of nondestructive evaluation (NDE) inspection can help to advance the inspectability and reliability of mechanical systems. However, NDE simulations applicable to non-idealized mechanical components often require large compute domains and long run times. This has prompted development of custom NDE simulation software tailored to high performance computing (HPC) hardware. Verification and validation (V&V) is an integral part of developing this software to ensure implementations are robust and applicable to inspection problems, producing tools and simulations suitable for computational NDE research. This presentation addresses factors common to V&V of several elastodynamic simulation codes applicable to ultrasonic NDE. Examples are drawn from in-house simulation software at NASA Langley Research Center, ranging from ensuring reliability in a 1D heterogeneous media wave equation solver to the V&V needs of 3D cluster-parallel elastodynamic software. Factors specific to a research environment are addressed, where individual simulation results can be as relevant as the software product itself. Distinct facets of V&V are discussed including testing to establish software reliability, employing systematic approaches for consistency with fundamental conservation laws, establishing the numerical stability of algorithms, and demonstrating concurrence with empirical data. This talk also addresses V&V practices for small groups of researchers. This includes establishing resources (e.g. time and personnel) for V&V during project planning to mitigate and control the risk of setbacks. Similarly, we identify ways for individual researchers to use V&V during simulation software development itself to both speed up the development process and reduce incurred technical debt.

NDE↗
NASA NTRS1982

NDE of simulated Space Shuttle tile disbonds

A technique which involves the use of ultrasonic Lamb waves for assaying the structural integrity of adhesive bonds between layered materials on thin metal plates, particularly with regard to the Shuttle TPS, is presented. The Lamb waves are generated by a pulse impact, resulting in surface waves propagating radially at 2.4 mm/microsec. Trials were performed with the sound waves applied to samples, of aluminum similar to the Orbiter external skin, which were coated with Teflon and a RTV silicone screed. The goal was to detect localized debonded areas or potentially debonded areas, which, during reentry, could result in blistering of the aluminum skin. The ultrasonic probes are described, noting the usage of broadband ultrasonic harmonics and a minicomputer processor. The testing system was found to accurately identify weakened bonds by the ratio of high and low frequency component areas of the received signal of the Lamb waves sent across the surface.

Ahlberg, L.↗
NASA NTRS2018

Lebedev Scheme for Ultrasound Simulation in Composites

The growing use of composite materials for aerospace applications has resulted in a need for quantitative nondestructive evaluation (NDE) methods appropriate for characterizing damage in composite components. NDE simulation tools, such as ultrasound models, can aid in enabling optimized inspection methods and establishing confidence in inspection capabilities. In this paper, a mathematical approach using the Lebedev Finite Difference (LFD) method is presented for ultrasonic wave simulation in composites. Boundary condition equations for implementing stress-free boundaries (necessary for simulation of NDE scenarios) are also presented. Quantitative comparisons between LFD guided wave ultrasound simulation results, experimental guided wave data, and dispersion curves are described. Additionally, stability tests are performed to establish the LFD code behavior in the presence of stress-free boundaries and low-symmetry anisotropy. Results show that LFD is an appropriate approach for simulating ultrasound in anisotropic composite materials and that the method is stable in the presence of low-symmetry anisotropy and stress-free boundaries. Studies presented in this paper include guided wave simulation in hexagonal, monoclinic, triclinic and layered composite laminates.

Guided wave↗
NASA NTRS2018

Comparison of Staggered Grid Finite Difference Schemes for Ultrasound Simulation in Curving Composites

The optimization of ultrasonic nondestructive evaluation (NDE) simulation tools for composites has the potential to reduce both individual part inspection time and overall certification time for composite parts and structures. Inspection guidance based on simulation provides increased confidence in the veracity of inspection results in addition to time reductions. This paper outlines ongoing work targeted to advance this objective through the use of finite difference (FD) simulation techniques formulated for composite structures with realistic geometries. Two staggered grid explicit FD schemes which show promise for this purpose are assessed: the Lebedev FD scheme and the rotated staggered grid (RSG) FD scheme. Algorithmic points which provide challenges for complex geometries are addressed, in particular handling of traction free surfaces and bi-material interfaces present at lamina boundaries. Code execution time estimates are performed as well to guide feasible domain sizes relative to algorithm choice and available hardware. Three test cases are simulated: a delaminated plate, a cylinder, and a triclinic lamina. These tests demonstrate that the Lebedev FD scheme needs additional work to handle inter-laminar interfaces and traction free boundaries in the presence of stair-stepping approximations. In contrast, the simple structure of the RSG unit cell makes it more straightforward to construct a 3D simulation technique for curved composite laminates.

Frankforter, Erik↗
NASA NTRS2014

NDE and SHM Simulation for CFRP Composites

Ultrasound-based nondestructive evaluation (NDE) is a common technique for damage detection in composite materials. There is a need for advanced NDE that goes beyond damage detection to damage quantification and characterization in order to enable data driven prognostics. The damage types that exist in carbon fiber-reinforced polymer (CFRP) composites include microcracking and delaminations, and can be initiated and grown via impact forces (due to ground vehicles, tool drops, bird strikes, etc), fatigue, and extreme environmental changes. X-ray microfocus computed tomography data, among other methods, have shown that these damage types often result in voids/discontinuities of a complex volumetric shape. The specific damage geometry and location within ply layers affect damage growth. Realistic threedimensional NDE and structural health monitoring (SHM) simulations can aid in the development and optimization of damage quantification and characterization techniques. This paper is an overview of ongoing work towards realistic NDE and SHM simulation tools for composites, and also discusses NASA's need for such simulation tools in aeronautics and spaceflight. The paper describes the development and implementation of a custom ultrasound simulation tool that is used to model ultrasonic wave interaction with realistic 3-dimensional damage in CFRP composites. The custom code uses elastodynamic finite integration technique and is parallelized to run efficiently on computing cluster or multicore machines.

Leckey, Cara A. C.↗
NASA NTRSDate not supplied

Computational Nondestructive Evaluation Case Studies at NASA

The state of the art of numerical simulation of nondestructive evaluations (NDE) has begun to transition from research to application. The simulation software, both commercial and custom, has reached a level of maturity where it can be readily deployed to solve real world problems. The next area of research that is beginning to emerge is determining when and how to NDE simulation should be applied. At NASA Langley Research Center, NDE simulations have already been utilized for several aerospace projects to facilitate or enhance understanding of the inspection optimization and interpretation of results. Researchers at NASA have identified several different scenarios where it is appropriate to utilized NDE simulations. In this presentation, we will describe these scenarios, give examples of each instance, and demonstrate how NDE simulations were applied to solve problems with an emphasis on the mechanics of integrating with other workgroups. These examples will include inspection planning for multi-layer pressure vessels as well as on-orbit inspections.

Peter D. Juarez↗
NASA NTRSDate not supplied

Simulation of Thermographic Responses of Delaminations in Composites with Quadrupole Method

Thermography has been shown to be a viable technique for inspection of composites. The quadrupole method is a valuable technique for rapidly simulating the thermal response of layered systems. Often, the effort has focused on a one-dimensional model, in particular for improved analysis of thermal data. For composites, the in-plane heat diffusion often significantly impacts the thermal response of defects of interest, therefore three-dimensional simulations are desirable. This paper discusses the extension of the quadrupole methodology to perform simulations of thermographic responses in three-dimensional configurations. This enables the more realistic simulations of the thermal response of delaminations in composites. The simulations are compared to finite element simulations of the same inspection configurations.

Thermography↗
NASA NTRSDate not supplied

Realistic Thermographic Simulation of Impact Damage with Quadrupole Method

Flash thermography has been shown to be an effective method for detection of delaminations in carbon fiber reinforced polymer (CFRP) composite structures. Improved understanding of thelimitations of the technique can be obtained by simulating the inspection process. Time domainfinite difference and finite element methods are well suited for such simulations but can be computationally intensive. An alternate method is to solve the Laplace transform of the heat equation, then invert the Laplace transform to produce a time domain response. Often this is referred to as the thermal quadrupole method and is well suited for simulating flash thermography. The quadrupole method has been used extensively for simulating one-dimensional heat flow in multilayer systems with contact resistances at the interfaces. It is also applicable for three dimensional configurations, in particular for simulation of changes in thermographic response due to delaminations in composites. This presentation discusses three-dimensional simulations with realistic shapes and contact resistances at the interfaces between layers. The results of these simulations are compared to thermography measurements on composites specimens with impact induced delaminations.

Thermography↗
NASA NTRS2010

Nondestructive Crack Detection in a Fuel System Component

The presentation examines the background and objective of nondestructive crack detection, flow control valve assembly and poppet post flight evaluation, poppet properties. magnetic property characterization of lab data, NDE, eddy current inspection, simulation, eddy current criteria, poppet cycle testing and NDE criteria, and the use of ultrasonic surface wave for crack detection.

Koshti, Ajay↗
NASA NTRS2021

Modeling of Guided Waves for Aerospace Applications

Advancements in computer hardware has led to new possibilities for rapid modeling and simulation capabilities across many scientific fields. Nondestructive evaluation (NDE) can benefit from increased use of simulation tools to guide optimization of inspection and health monitoring methods, enhance understanding of data, aid in development of defect characterization methods, and generate data sets for use with machine learning and model-assisted probability of detection. Recent work at NASA has entailed development and benchmarking of both custom simulation codes and commercial simulation tools for ultrasonic wave propagation. This paper describes recent work at NASA in modeling of guided waves in composites and other aerospace materials. Results and computational speeds for a composite benchmark case are reported for a custom finite difference Rotated Staggered Grid code and for the commercial finite element software package, Pogo. Recent progress in linking NDE models to parametric analysis tools is also discussed.

Nondestructive evaluation↗
NASA NTRS2019

Assessing Reliability of NDE Flaw Detection Using Smaller Number of Demonstration Data Points

The paper provides an engineering analysis approach for assessing reliability of NDE flaw detection using smaller number of demonstration data points. It explores dependence of probability of detection (POD), probability of false positive (POF), on contrast-to-noise ratio, and net decision threshold-to-noise ratio in a simulated data; and draws some generically applicable inferences to devise the approach. ASTM nondestructive evaluation standards provide requirements on signal-to-noise ratio and/or contrast-to-noise ratio in order to provide reliable flaw detection and limit false positive calls. POD analysis of inspection test data results in an estimated flaw size, denoted by 𝑎90/95. This flaw size has 90% POD and minimum 95% confidence. POF is also estimated in the analysis. POD demonstration requires specimens with flaws of known size. In many situations, it is very expensive to produce the large number of flaws required for the POD analysis. In some situations, only real flaws can truly represent the flaws for demonstration. Real flaws of correct size and location in part configuration specimen may be difficult to produce, if not impossible. Here, an engineering analysis approach is devised using simulation to assess reliability of NDE technique when a limited number of flaws are available for demonstration. In this simulation, a technique is considered reliable, if it provides flaw detectability size equal to or better than the theoretical 𝑎90𝑡ℎ used in simulation and also provides a POF less than or equal to a chosen value. The paper uses simulated signal response versus flaw size data to devise the approach. Linear correlation is used between the signal response data and flaw size. POD software mh1823 uses generalized linear model (GLM) in POD analysis after transforming the flaw size and signal response, if needed, using logarithm. Therefore, this approach is in agreement with the linear signal correlation used in mh1823. Using the POD analysis of data, generic conditions on contrast-to-noise ratio and net decision threshold-to-noise ratio are derived for reliable flaw detection. In order to assess technique reliability using the engineering approach, signal response-to-flaw size correlation about the flaw size of concern is needed. In addition, measurement of noise is also needed. If the technique meets the above requirements, assumption of linear signal-to-flaw size correlation and conditions on noise, then the technique can be assessed using this analysis as it fits the underlying POD model used here. The approach is conservative and is designed to provide a larger flaw size compared to the POD approach. Such NDE technique assessment approach, although, not as rigorous as POD, can be cost effective if the larger flaw size can be tolerated. Typically, this is a situation for all quality control NDE inspections. Here, an NDE technique needs to be reliable and 𝑎90/95 is not estimated, but the assessed flaw size is assumed to be larger than the unknown a90 due to conservative factors or margins. Applicability of the approach for assessing reliability of flaw detection in x-ray radiography and 2D imaging in general is also explored.

Koshti, Ajay M.↗
NASA NTRS1990

Review of acousto-ultrasonic NDE for composites

Acousto-ultrasonics utilizes simulated stress waves to detect and quantify defect states, damage conditions, and variations of mechanical properties in fiber reinforced composites. The term acousto-ultrasonics denotes a combination of aspects of acoustic emission methodology with ultrasonic materials characterization. The acousto-ultrasonic approach was developed to deal primarily with evaluation of the integrated effect of minor flaws and diffuse flaw populations of subcritical flaws in composite and bonded structures. These factors singly and collectively also influence acousto-ultrasonic measurements that, in turn, correlate with dynamic response and mechanical property variations. Since it was first introduced, the acousto-ultrasonic approach was successfully applied to a variety of materials, including polymeric, metallic, and ceramic matrix composites; adhesively bonded materials; paper and wood products; cable and rope; and also human bone. Examples of applications and limitations of the approach are reviewed. Basic methods and guidelines are discussed. The underlying hypothesis and theory development needs are indicated.

Vary, Alex↗