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At least 19 records

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NASA NTRS2011

Development of Passive Fuel Cell Thermal Management Technology

The NASA Glenn Research Center is developing advanced passive thermal management technology to reduce the mass and improve the reliability of space fuel cell systems for the NASA exploration program. The passive thermal management system relies on heat conduction within the cooling plate to move the heat from the central portion of the cell stack out to the edges of the fuel cell stack rather than using a pumped loop cooling system to convectively remove the heat. Using the passive approach eliminates the need for a coolant pump and other cooling loop components which reduces fuel cell system mass and improves overall system reliability. Previous analysis had identified that low density, ultra-high thermal conductivity materials would be needed for the cooling plates in order to achieve the desired reductions in mass and the highly uniform thermal heat sink for each cell within a fuel cell stack. A pyrolytic graphite material was identified and fabricated into a thin plate using different methods. Also a development project with Thermacore, Inc. resulted in a planar heat pipe. Thermal conductivity tests were done using these materials. The results indicated that lightweight passive fuel cell cooling is feasible.

Burke, Kenneth A.↗

NASA NTRS2012

Demonstration of Passive Fuel Cell Thermal Management Technology

The NASA Glenn Research Center is developing advanced passive thermal management technology to reduce the mass and improve the reliability of space fuel cell systems for the NASA Exploration program. The passive thermal management system relies on heat conduction within highly thermally conductive cooling plates to move the heat from the central portion of the cell stack out to the edges of the fuel cell stack. Using the passive approach eliminates the need for a coolant pump and other cooling loop components within the fuel cell system which reduces mass and improves overall system reliability. Previous development demonstrated the performance of suitable highly thermally conductive cooling plates and integrated heat exchanger technology to collect the heat from the cooling plates (Ref. 1). The next step in the development of this passive thermal approach was the demonstration of the control of the heat removal process and the demonstration of the passive thermal control technology in actual fuel cell stacks. Tests were run with a simulated fuel cell stack passive thermal management system outfitted with passive cooling plates, an integrated heat exchanger and two types of cooling flow control valves. The tests were run to demonstrate the controllability of the passive thermal control approach. Finally, successful demonstrations of passive thermal control technology were conducted with fuel cell stacks from two fuel cell stack vendors.

Burke, Kenneth A.↗

NASA NTRS2010

Fast-Response-Time Shape-Memory-Effect Foam Actuators

Bulk shape memory alloys, such as Nitinol or CuAlZn, display strong recovery forces undergoing a phase transformation after being strained in their martensitic state. These recovery forces are used for actuation. As the phase transformation is thermally driven, the response time of the actuation can be slow, as the heat must be passively inserted or removed from the alloy. Shape memory alloy TiNi torque tubes have been investigated for at least 20 years and have demonstrated high actuation forces [3,000 in.-lb (approximately equal to 340 N-m) torques] and are very lightweight. However, they are not easy to attach to existing structures. Adhesives will fail in shear at low-torque loads and the TiNi is not weldable, so that mechanical crimp fits have been generally used. These are not reliable, especially in vibratory environments. The TiNi is also slow to heat up, as it can only be heated indirectly using heater and cooling must be done passively. This has restricted their use to on-off actuators where cycle times of approximately one minute is acceptable. Self-propagating high-temperature synthesis (SHS) has been used in the past to make porous TiNi metal foams. Shape Change Technologies has been able to train SHS derived TiNi to exhibit the shape memory effect. As it is an open-celled material, fast response times were observed when the material was heated using hot and cold fluids. A methodology was developed to make the open-celled porous TiNi foams as a tube with integrated hexagonal ends, which then becomes a torsional actuator with fast response times. Under processing developed independently, researchers were able to verify torques of 84 in.-lb (approximately equal to 9.5 Nm) using an actuator weighing 1.3 oz (approximately equal to 37 g) with very fast (less than 1/16th of a second) initial response times when hot and cold fluids were used to facilitate heat transfer. Integrated structural connections were added as part of the net shape process, eliminating the need for welding, adhesives, or mechanical crimping. Inexpensive net-shape processing was used, which reduces the cost of the actuator by over a factor of 10 over nonporous TiNi made by hot drawing of tube or electrical discharge machining. By forming the alloy as an open-celled foam, the surface area for heat transfer is dramatically increased, allowing for much faster response times. The technology also allows for netshape fabrication of the actuator, which allows for structural connections to be integrated into the actuator material, making these actuators significantly less expensive. Commercial applications include actuators for concepts such as the variable area chevron and nozzle in jet aircraft. Lightweight tube or rod components can be supplied to interested parties.

Jardine, Peter↗

NASA NTRS2011

Modeling a Transient Pressurization with Active Cooling Sizing Tool

As interest in the area of in-space zero boil-off cryogenic propellant storage develops, the need to visualize and quantify cryogen behavior during ventless tank self-pressurization and subsequent cool-down with active thermal control has become apparent. During the course of a mission, such as the launch ascent phase, there are periods that power to the active cooling system will be unavailable. In addition, because it is not feasible to install vacuum jackets on large propellant tanks, as is typically done for in-space cryogenic applications for science payloads, instances like the launch ascent heating phase are important to study. Numerous efforts have been made to characterize cryogenic tank pressurization during ventless cryogen storage without active cooling, but few tools exist to model this behavior in a user-friendly environment for general use, and none exist that quantify the marginal active cooling system size needed for power down periods to manage tank pressure response once active cooling is resumed. This paper describes the Transient pressurization with Active Cooling Tool (TACT), which is based on a ventless three-lump homogeneous thermodynamic self-pressurization model1 coupled with an active cooling system estimator. TACT has been designed to estimate the pressurization of a heated but unvented cryogenic tank, assuming an unavailable power period followed by a given cryocooler heat removal rate. By receiving input data on the tank material and geometry, propellant initial conditions, and passive and transient heating rates, a pressurization and recovery profile can be found, which establishes the time needed to return to a designated pressure. This provides the ability to understand the effect that launch ascent and unpowered mission segments have on the size of an active cooling system. A sample of the trends found show that an active cooling system sized for twice the steady state heating rate would results in a reasonable time for tank pressure recovery with ZBO of a liquid oxygen propellant tank.

Guzik, Monica C.↗

NASA NTRS1977

Removing CO2 and moisture from air

Foamed-aluminum blocks act as passive heat exchanger to improve efficiency. Improved closed-cycle atmospheric scrubber, level of carbon dioxide, and water vapor are reduced without affecting temperature of airstream. Exchangers draw impurities from air without additional heaters of auxillary equipment.

Tepper, E. H.↗

NASA NTRS2023

NASA Team Develops a Test Article to Demonstrate “Zero Boil-Off” Storage of Liquid Hydrogen via Cryocoolers and a Two-Stage Cooling Approach

Funded by NASA’s Technology Demonstration Mission Program and managed by the Cryogenic Fluid Management Portfolio Project, a NASA team is developing a test article to demonstrate the “zero boil-off” storage of liquid hydrogen using active cooling (cryocoolers) and a two-stage cooling approach. The current state of the art for storage of liquid hydrogen on-orbit is on the order of hours while future missions may require storage for months or even years. To enable such extended storage durations, “near zero” propellant loss, or “zero boil-off”, must be achieved. This may be accomplished with the implementation of “near zero” leakage components, a high performing suite of passive technologies to minimize the environmental heat loads, and active cooling via cryocoolers to intercept and remove heat from the propellant tanks and associated structure. Of course, with any cryogenic vehicle and mission, a mass and power trade should be conducted to determine if it is indeed feasible to carry the additional dry mass associated with active cooling, or if one could simply carry additional propellants to accommodate propellant loss which is typically not an option for a long duration mission.

Hydrogen Storage↗

NASA NTRSDate not supplied

High-Enthalpy Testing to Validate Simulation of an Aerosol Capture Probe

AERACEPT (Aerosol Rapid Analysis Combined Entry Probe/sonde Technology) is a developing technology enabling in-situ aerosol particle sampling and analysis in a small spacecraft mission envelope. It integrates a passive aerosol sample collection system into a probe’s thermal protection system (TPS) to remove the need for heat shield separation and active descent control (parachutes, gliders, etc.). AERACEPT is being validated against the requirements of the Nephele mission concept, which targets the middle and lower Venus cloud layers. The proposed technology employs 3D Carbon-Carbon (3D-CC) at the probe’s nose to withstand the extreme environments encountered in a Venus entry without producing pyrolysis gases that would contaminate the mission sample collection. Any shape change of this 3D-CC sample inlet will affect airflow through the sampling system, thereby impacting aerosol sample collection bias and efficiency. Accurate prediction of the nose’s material response during entry is there-fore of fundamental importance to the development and practical use of this technology. As a result, the AERACEPT project is planning a test campaign in the newly built PlasmatronX facility with a novel “Open Iso-Q” test article to validate state-of-the-art material response tools for a simulated Venus entry. The PlasmatronX is a 350 kW inductively-coupled plasma facility developed and run by the Center for Hypersonics and Entry Systems Studies at the University of Illinois at Urbana-Champaign. The facility can support ground testing for a variety of planetary destinations by simulating entry conditions in Nitrogen, Air, and Carbon Dioxide. To best simulate the Venus atmosphere and match flight-like recession, the planned AERACEPT test campaign will use Carbon Dioxide as its test gas. AERACEPT has designed two test articles for this campaign: 1) a standard test article whose curved surface approximates a constant applied heat flux (“Closed Iso-Q” model) and 2) a novel inlet test article with a through-hole at the stagnation point (“Open Iso-Q” model). Both article types consist of a 3D-CC sample bonded to a graphite fixture. All articles will be laser scanned before and after testing to estimate shape change and recession, and the “Closed Iso-Q” articles will be instrumented with thermocouples to provide temperature histories. The test article temperatures and inlet shape change will be compared against simulations run with the Porous material Analysis Toolbox based on OpenFOAM (PATO) to validate the AERACEPT 3D-CC material response model. Due to the high thermal conductivity of 3D-CC, multidimensional effects have a large influence on the test article temperature and the standard 1-D material response tools are not sufficient for test planning. The test campaign features (e.g. article design, run duration, heat fluxes) are therefore informed by a series of 3-D simulations using state-of-the-art material response tools such as PATO. The test campaign is scheduled for spring of 2024. Expected results include 1) Key drivers of selected test conditions (e.g. matching mission flight atmosphere & recession), 2) Simulation results that informed test article design, 3) Acquired test data such as recession measurements, temperature histories, and photos, and 4) Comparisons between test results and simulation predictions.

AERACEPT↗

NASA NTRSDate not supplied

High-Enthalpy Testing to Validate Simulation of an Aerosol Capture Probe

AERACEPT↗

NASA NTRS2016

Optimized Heat Pipe Backup Cooling System Tested with a Stirling Convertor

In a Stirling Radioisotope Power System (RPS), heat must be continuously removed from the General Purpose Heat Source (GPHS) modules to maintain the modules and surrounding insulation at acceptable temperatures. The Stirling convertor normally provides this cooling. If the Stirling convertor stops in the current system, the insulation is designed to spoil, preventing damage to the GPHS at the cost of an early termination of the mission. An alkali-metal variable conductance heat pipe (VCHP) can be used to passively allow multiple stops and restarts of the Stirling convertor by bypassing the heat during stops. In a previous NASA Small Business Innovation Research (SBIR) Program, Advanced Cooling Technologies, Inc. (ACT) developed a series of sodium VCHPs as backup cooling systems for the Stirling RPS. In 2012, one of these VCHPs was successfully tested at NASA Glenn Research Center with a Stirling convertor as an Advanced Stirling Radioisotope Generator (ASRG) backup cooling system. The prototype; however, was not optimized and did not reflect the final heat rejection path. ACT through further funding has developed a semioptimized prototype with the finalized heat path for testing at Glenn with a Stirling convertor. The semioptimized system features a two-phase radiator and is significantly smaller and lighter than the prior prototype to reflect a higher level of flight readiness. The VCHP is designed to activate and remove heat from the GPHS during stoppage with a small temperature increase from the nominal vapor temperature. This small temperature increase from nominal is low enough to avoid risking standard ASRG operation and spoiling of the multilayer insulation (MLI). The VCHP passively allows the Stirling convertor to be turned off multiple times during a mission with potentially unlimited off durations. Having the ability to turn the Stirling off allows for the Stirling to be reset and reduces vibrations on the platform during sensitive measurements or procedures. This paper presents the design of the VCHP and its test results with a Stirling convertor at Glenn. Tests were carried for multiple on and off cycles to demonstrate repeatability. The impacts associated with the addition of the VCHP to the system are also addressed in terms of mass and additional heat losses due to the presence of the VCHP.

Heat Pipe↗

NASA NTRS2018

Design and Development of a Laboratory-Scale Ice Adhesion Testing Device

When an aircraft traverses through clouds containing supercooled water droplets, in-flight icing can occur that negatively affects vehicle performance by increasing weight and drag leading to loss of lift. Super-cooled water droplets present in clouds that impact vehicle surfaces can lead to inflight icing any time during the year.1 Most events occur at temperatures ranging from 0 to -20degC. Ice generated on the aircraft can vary between clear/glaze, rime, and mixed (Fig. 1) depending on air temperature (-5 to -20degC), liquid water content (0.3-0.6 g/m3), and droplet size (median volumetric diameter of 15-40 μm). Current strategies to remove ice are based on active technologies such as pneumatic boots, heated surfaces, and deicing agents (i.e., ethylene- and propylene-based glycols). The latter have potential environmental concerns. A passive approach to mitigate accreting ice that is actively being investigated are protective coatings. An ice mitigating coating could potentially be used as a stand-alone material, but more likely in combination with an active approach. In the latter scenario, potential reduction in power consumption by the active approach may be realized. To determine the ice adhesion strength of impact ice that is representative of the aircraft environment is not a trivial matter. Test methods utilizing slowly formed ice (i.e., freezer ice) do not accurately simulate this environment. Likewise, some testing methodologies involve sample relocation from the icing environment to the test chamber that can result in thermal shock to the sample, thus affecting the results. The Adverse Environment Rotor Test Stand (AERTS) located at Pennsylvania State University (PSU) has been demonstrated to simulate impact icing conditions within the icing envelope for the determination of ice adhesion shear strength (IASS) without removal/relocation of the sample.2 Due to the confidence in results obtained from AERTS, this instrument is in high demand and requires a significant amount of lead time and capital investment to obtain IASS results. As a solution for quickly and economically screening coatings in a controlled manner under impact icing conditions, a laboratory-scale ice adhesion test and dead blades were then removed from the rotor/blade assembly to obtain the final mass. The IASS of the live blade was determined from the difference in mass (before and after testing) of the live and dead blades, the ice shed area, and the rpm of the shed event. The same live blade sample was tested in triplicate at all three test temperatures. Surface roughness was determined using a Bruker Dektak XT Stylus Profilometer. Measurements were conducted using a 12.5 μm tip at a vertical range of 65.5 μm with an applied force of 3 mg. Data were collected over a 1.0 mm length at a resolution of 0.056 μm/point. Five single line scans at different locations were collected and processed using a two-point leveling subtraction. The resultant Ra (arithmetic roughness) and Rq (root mean square roughness) average values were calculated.

Smith, Joseph G., Jr.↗

NASA NTRS2013

Method to Increase Performance of Foil Bearings Through Passive Thermal Management

This invention is a new approach to designing foil bearings to increase their load capacity and improve their reliability through passive thermal management. In the present case, the bearing is designed in such a way as to prevent the carryover of lubricant from the exit of one sector to the inlet of the ensuing sector of the foil bearing. When such passive thermal management techniques are used, bearing load capacity is improved by multiples, and reliability is enhanced when compared to current foil bearings. This concept has recently been tested and validated, and shows that load capacity performance of foil bearings can be improved by a factor of two at relatively low speeds with potentially greater relative improvements at higher speeds. Such improvements in performance with respect to speed are typical of foil bearings. Additionally, operation of these newly conceived bearings shows much more reliability and repeatable performance. This trait can be exploited in machine design to enhance safety, reliability, and overall performance. Finally, lower frictional torque has been demonstrated when operating at lower (non-load capacity) loads, thus providing another improvement above the current state of the art. The objective of the invention is to incorporate features into a foil bearing that both enhance passive thermal management and temperature control, while at the same time improve the hydrodynamic (load capacity) performance of the foil bearing. Foil bearings are unique antifriction devices that can utilize the working fluid of a machine as a lubricant (typically air for turbines and motors, liquids for pumps), and as a coolant to remove excess energy due to frictional heating. The current state of the art of foil bearings utilizes forced cooling of the bearing and shaft, which represents poor efficiency and poor reliability. This invention embodies features that utilize the bearing geometry in such a manner as to both support load and provide an inherent and passive cooling mechanism. This cooling mechanism functions in such a way as to prevent used (higher temperature) lubricant from being carried over from the exit of one sector into the entry of the next sector of the foil bearing. The disclosed innovation is an improved foil bearing design that reduces or eliminates the need for force cooling of the bearing, while at the same time improving the load capacity of the bearing by at least a factor of two. These improvements are due to the elimination of lubricant carryover from the trailing edge of one sector into the leading edge of the next, and the mixing of used lubricant with the surrounding ambient fluid.

Bruckner, Robert↗

NASA NTRS1988

Status of the US Space Station ECLSS and internal TCS

The U.S. Space Station includes many elements and systems. Responsibility for these have been delegated to four NASA centers via a work packaging concept. Marshall Space Flight Center (MSFC) is responsible for work package one (WPOI) which includes the habitation, laboratory modules, the logistic carrier elements, as well as the environmental control and life support system (ECLSS), the internal thermal control system (ITCS), and the internal audio and video systems. Current status of the ECLSS and internal thermal are the subjects of this paper. The ECLSS is composed of six subsystem groups: the temperature humidity control, the atmosphere control and supply, the air revitalization, water reclamation and management, fecal waste management, and the fire detection and suppression subsystems. The internal TCS consists of all WP01 elements of passive and active thermal measures. The ECLSS and ITCS provide services for the permanently orbiting pressurized modules as well as the pressurized and unpressurized logistics carriers. The logistics carriers are used as ground-to-station ferries for both resupply and initial delivery of selected new equipment and later replacement items. Equipment, which cannot be subjected to the rigors of the space environment, will be carried in the pressurized logistic carrier; while an unpressurized carrier is used to resupply other commodities, such as external fluid consumables. The laboratory module houses the equipment for both payloads and subsystem maintenance and repair. The habitation module is dedicated to providing living and sleeping quarters including a galley, sleeping provisions, hygiene facilities, medical services as well as services for exercise and relaxation. The four nodes that join the two modules at their ends also house electronics as well as work stations and outside viewing cupolas. The airlocks, one providing an emergency hyperbaric chamber capability, are also attached. This assembly constitutes the U.S. provided portion of the initial station. Additional international modules and docking provisions for future attached pressurized payload as well as dual logistic module and growth capabilities are also provided. The primary heat rejection mechanism is achieved via a central set of radiators provided by another work package. The interface with the central TCS at the module heat exchangers defines the active control interface boundary of the ITCS with the central TCS. All internal cooling of the permanent orbital elements are provided via internal active fluid loops within the elements utilizing water as the transport media. Cabin and equipment cooling are provided by forced air flow and cold plate heat sinks. A special active cooling loop is provided in the laboratory module to accommodate experiments and other payloads. Coatings and insulation are used in conjunction with the active components to passively limit heat losses/gains. The most challenging ECLSS new technology issues relate to oxygen and water recovery. Closure of the oxygen loop requires the use of new regenerative CO 2 removal and concentration techniques, CO 2 reduction to convert the CO 2 to water with a waste by-product, and the electrolysis of water to produce breathing oxygen for water recovery. For water recovery three separate loops are currently planned. One loop provides potable water by utilizing a combination of recovered condensate and CO 2 reduction water. A second loop purifies hygiene water from waste from the showers, clothes washer, hygiene/hand wash stations and a dishwasher. The third loop provides hygiene water by the reclamation and purification of urine water. This paper outlines the basic services provided by the ECLSS and ITCS and describes the ECLSS functional distribution throughout the pressurized assembly.

R. Humphries↗

NASA NTRS1980

Active heat exchange system development for latent heat thermal energy storage

Various active heat exchange concepts were identified from among three generic categories: scrapers, agitators/vibrators and slurries. The more practical ones were given a more detailed technical evaluation and an economic comparison with a passive tube-shell design for a reference application (300 MW sub t storage for 6 hours). Two concepts were selected for hardware development: (1) a direct contact heat exchanger in which molten salt droplets are injected into a cooler counterflowing stream of liquid metal carrier fluid, and (2) a rotating drum scraper in which molten salt is sprayed onto the circumference of a rotating drum, which contains the fluid salt is sprayed onto the circumference of a rotating drum, which contains the fluid heat sink in an internal annulus near the surface. A fixed scraper blade removes the solidified salt from the surface which was nickel plated to decrease adhesion forces. In addition to improving performance by providing a nearly constant transfer rate during discharge, these active heat exchanger concepts were estimated to cost at least 25% less than the passive tube-shell design.

Alario, J.↗

NASA NTRS2001

Cryogenic Propellant Long-Term Storage With Zero Boil-Off

Significant boil-off losses from cryogenic propellant storage systems in long-duration space mission applications result in additional propellant and larger tanks. The potential propellant mass loss reductions with the Zero Boil-off (ZBO) concept are substantial; therefore, further exploration through technology programs has been initiated within NASA. A large-scale demonstration of the ZBO concept has been devised utilizing the Marshall Space Flight Center (MSFC) Multipurpose Hydrogen Test Bed (MHTB) along with a cryo-cooler unit. The ZBO concept consists of an active cryo-cooling system integrated with traditional passive thermal insulation. The cryo-cooler is interfaced with the MHTB and spraybar recirculation/mixer system in a manner that enables thermal energy removal at a rate that equals the total tank heat leak. The liquid hydrogen (LH2) is withdrawn from the tank, passed through a heat exchanger, and then the chilled liquid is sprayed back into the tank through a spraybar. The test series will be performed over a 20-30 day period. Tests will be conducted at multiple fill levels to demonstrate concept viability and to provide benchmark data to be used in analytical model development. In this paper the test set-up and test procedures are presented.

Hedayat, Ali↗

NASA NTRS2006

NASA's Spitzer Space Telescope's Operational Mission Experience

New Generation of Detector Arrays(100 to 10,000 Gain in Capability over Previous Infrared Space Missions). IRAC: 256 x 256 pixel arrays operating at 3.6 microns, 4.5 microns, 5.8 microns, 8.0 microns. MIPS: Photometer with 3 sets of arrays operating at 24 microns, 70 microns and 160 microns. 128 x 128; 32 x 32 and 2 x 20 arrays. Spectrometer with 50-100 micron capabilities. IRS: 4 Array (128x128 pixel) Spectrograph, 4 -40 microns. Warm Launch Architecture: All other Infrared Missions launched with both the telescope and scientific instrument payload within the cryostat or Dewar. Passive cooling used to cool outer shell to approx.40 K. Cryogenic Boil-off then cools telescope to required 5.5K. Earth Trailing Heliocentric Orbit: Increased observing efficiency, simplification of observation planning, removes earth as heat source.

space telescopes↗

NASA NTRS1975

Lightweight fuel cell powerplant for Tug

The design and characteristics of a lightweight powerplant based on advanced cell technology to meet the requirements of the Space Tug are described. The powerplant can be operated off low-pressure hydrogen and oxygen rocket propellant tanks and avoid the need for a dedicated reactant supply. Product water can be condensed or not, depending on vehicle or payload requirements. The heart of the unit, the fuel cell power section, consist of lightweight, series-connected, alkaline cells, while the power section contains accessory components for reactant conditioning, distribution, and venting, coolant circulation, passive product water removal and electric control. The proposed design offers at least a 50 per cent saving in powerplant weight, so that the total estimated powerplant dry weight including structure, tubing, wiring, interface connectors, and interface heat exchanger is 48 lb.

Handley, L. M.↗

NASA NTRS2011

Characterization Testing of the Teledyne Passive Breadboard Fuel Cell Powerplant

NASA's Exploration Technology Development Program (ETDP) is tasked with the development of enabling and enhancing technologies for NASA's exploration missions. As part of that initiative, the return to the Moon requires a reliable, efficient, and lightweight fuel cell powerplant system to provide power to the Altair Lunar Lander and for lunar surface systems. Fuel cell powerplants are made up of two basic parts; the fuel cell itself and the supporting ancillary subsystem. This subsystem is designed to deliver reactants to the fuel cell and remove product water and waste heat from the fuel cell. Typically, fuel cell powerplant ancillary subsystems rely upon pumps and active water separation techniques to accomplish these tasks for closed hydrogen/oxygen systems. In a typical system, these components are the largest contributors to the overall parasitic power load of the fuel cell powerplant. A potential step towards the development of an efficient lightweight power system is to maximize the use of "passive" or low-power ancillary components as a replacement to these high-power load components

Loyselle, Patricia↗

NASA NTRS2016

Combining Passive Thermography and Acoustic Emission for Large Area Fatigue Damage Growth Assessment of a Composite Structure

Passive thermography and acoustic emission data were obtained for improved real time damage detection during fatigue loading. A strong positive correlation was demonstrated between acoustic energy event location and thermal heating, especially if the structure under load was nearing ultimate failure. An image processing routine was developed to map the acoustic emission data onto the thermal imagery. This required removing optical barrel distortion and angular rotation from the thermal data. The acoustic emission data were then mapped onto thermal data, revealing the cluster of acoustic emission event locations around the thermal signatures of interest. By combining both techniques, progression of damage growth is confirmed and areas of failure are identified. This technology provides improved real time inspections of advanced composite structures during fatigue testing.Keywords: Thermal nondestructive evaluation, fatigue damage detection, aerospace composite inspection, acoustic emission, passive thermography

Zalameda, Joseph N.↗