Engineering topics

Cramer, K. Elliott

Publications and source records attributed to Cramer, K. Elliott.

At least 37 records · Page 2

NASA NTRS2007

Results of On-Orbit Testing of an Extra-Vehicular Infrared Camera Inspection System

This paper will discuss an infrared camera inspection system that has been developed to allow astronauts to demonstrate the ability to inspect reinforced carbon-carbon (RCC) components on the space shuttle as part of extra-vehicular activities (EVA) while in orbit. Presented will be the performance of the EVA camera system coupled with solar heating for inspection of damaged RCC specimens and NDE standards. The data presented was acquired during space shuttle flights STS-121 and STS-115 as well during a staged EVA from the ISS. The EVA camera system was able to detect flatbottom holes as small as 2.54cm in diameter with 25% material loss. Results obtained are shown to be comparable to ground-based thermal inspections performed in the laboratory using the same camera and simulated solar heating. Data on both the time history of the specimen temperature and the ability of the inspection system to image defects due to impact will likewise be presented.

Howell, Patricia A.↗

NASA NTRS2007

Device and Method for Connections Made Between a Crimp Connector and Wire

An ultrasonic device and method obtains desirable crimp connections between a crimp connector and a wire, or bundle of wires, by assessing the desirability of connections made in a wire-to-wire connection and in other situations where two materials with good acoustic propagation characteristics are joined together via deformation. An embodiment of the device as a crimping tool comprises a compressing means, pulse-generating circuitry. at least one ultrasonic transmitting transducer, at least one ultrasonic receiving transducer, receiving circuitry, and a display. The user may return to a previously crimped connection and assess the desirability of the connection by compressing the device about the connection, sending an acoustic signal through the crimp, andco111paring the received signal to a signal obtained from known desirable connections.

Yost, William T.↗

NASA NTRS2007

Wire Crimp Connectors Verification using Ultrasonic Inspection

The development of a new ultrasonic measurement technique to quantitatively assess wire crimp connections is discussed. The amplitude change of a compressional ultrasonic wave propagating through the junction of a crimp connector and wire is shown to correlate with the results of a destructive pull test, which previously has been used to assess crimp wire junction quality. Various crimp junction pathologies (missing wire strands, incorrect wire gauge, incomplete wire insertion in connector) are ultrasonically tested, and their results are correlated with pull tests. Results show that the ultrasonic measurement technique consistently (as evidenced with pull-testing data) predicts good crimps when ultrasonic transmission is above a certain threshold amplitude level. A physics-based model, solved by finite element analysis, describes the compressional ultrasonic wave propagation through the junction during the crimping process. This model is in agreement within 6% of the ultrasonic measurements. A prototype instrument for applying the technique while wire crimps are installed is also presented.

Cramer, K. Elliott↗

NASA NTRS2007

Status of Thermal NDT of Space Shuttle Materials at NASA

Since the Space Shuttle Columbia accident, NASA has focused on improving advanced NDE techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter s wing leading edge and nose cap. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Details of the analysis technique that has been developed to allow insitu inspection of a majority of shuttle RCC components is discussed. Additionally, validation testing, performed to quantify the performance of the system, will be discussed. Finally, the results of applying this technology to the Space Shuttle Discovery after its return from the STS-114 mission in July 2005 are discussed.

Cramer, K. Elliott↗

NASA NTRS2006

Method and Apparatus for the Portable Identification Of Material Thickness And Defects Along Uneven Surfaces Using Spatially Controlled Heat Application

A method and apparatus for testing a material such as the water-wall tubes in boilers includes the use of a portable thermal line heater having radiation shields to control the amount of thermal radiation that reaches a thermal imager. A procedure corrects for variations in the initial temperature of the material being inspected. A method of calibrating the testing device to determine an equation relating thickness of the material to temperatures created by the thermal line heater uses empirical data derived from tests performed on test specimens for each material type, geometry, density, specific heat, speed at which the line heater is moved across the material and heat intensity.

Reilly, Thomas L.↗

NASA NTRS2006

The Application of Principal Component Analysis Using Fixed Eigenvectors to the Infrared Thermographic Inspection of the Space Shuttle Thermal Protection System

The Nondestructive Evaluation Sciences Branch at NASA s Langley Research Center has been actively involved in the development of thermographic inspection techniques for more than 15 years. Since the Space Shuttle Columbia accident, NASA has focused on the improvement of advanced NDE techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter s wing leading edge. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can be used to inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Principal Component Analysis (PCA) has been shown effective for reducing thermographic NDE data. A typical implementation of PCA is when the eigenvectors are generated from the data set being analyzed. Although it is a powerful tool for enhancing the visibility of defects in thermal data, PCA can be computationally intense and time consuming when applied to the large data sets typical in thermography. Additionally, PCA can experience problems when very large defects are present (defects that dominate the field-of-view), since the calculation of the eigenvectors is now governed by the presence of the defect, not the good material. To increase the processing speed and to minimize the negative effects of large defects, an alternative method of PCA is being pursued when a fixed set of eigenvectors is used to process the thermal data from the RCC materials. These eigen vectors can be generated either from an analytic model of the thermal response of the material under examination, or from a large cross section of experimental data. This paper will provide the details of the analytic model; an overview of the PCA process; as well as a quantitative signal-to-noise comparison of the results of performing both embodiments of PCA on thermographic data from various RCC specimens. Details of a system that has been developed to allow insitu inspection of a majority of shuttle RCC components will be presented along with the acceptance test results for this system. Additionally, the results of applying this technology to the Space Shuttle Discovery after its return from flight will be presented.

Cramer, K. Elliott↗

NASA NTRS2006

Status of Thermal NDT of Space Shuttle Materials at NASA

Since the Space Shuttle Columbia accident, NASA has focused on improving advanced nondestructive evaluation (NDE) techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter's wing leading edge and nose cap. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Details of the analysis technique that has been developed to allow insitu inspection of a majority of shuttle RCC components is discussed. Additionally, validation testing, performed to quantify the performance of the system, will be discussed. Finally, the results of applying this technology to the Space Shuttle Discovery after its return from the STS-114 mission in July 2005 are discussed.

Cramer, K. Elliott↗

NASA NTRS2006

Marking Electrical Wiring With Condition Indicators

A method is provided for marking electrical Wiring with condition indicators. One or more markers are added to one or both of the insulative material and a surface of an electrical conductor such that it bonds thereto. Each marker is capable of emanating into a surrounding atmospheric environment as a gaseous effluent in response to a specific condition experienced by the electrical conductor.

Yost, William T.↗

NASA NTRS2006

Status of Thermal NDT of Space Shuttle Materials at NASA

Since the Space Shuttle Columbia accident, NASA has focused on improving advanced NDE techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter's wing leading edge and nose cap. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Details of the analysis technique that has been developed to allow insitu inspection of a majority of shuttle RCC components is discussed. Additionally, validation testing, performed to quantify the performance of the system, will be discussed. Finally, the results of applying this technology to the Space Shuttle Discovery after its return from the STS-114 mission in July 2005 are discussed.

Cramer, K. Elliott↗

NASA NTRS2005

Infrared On-Orbit Inspection of Shuttle Orbiter Reinforced Carbon-Carbon Using Solar Heating

Thermographic nondestructive inspection techniques have been shown to provide quantitative, large area damage detection capabilities for the ground inspection of the reinforced carbon-carbon (RCC) used for the wing leading edge of the Shuttle orbiter. The method is non-contacting and able to inspect large areas in a relatively short inspection time. Thermal nondestructive evaluation (NDE) inspections have been shown to be applicable for several applications to the Shuttle in preparation for return to flight, including for inspection of RCC panels during impact testing, and for between-flight orbiter inspections. The focus of this work is to expand the capabilities of the thermal NDE methodology to enable inspection by an astronaut during orbital conditions. The significant limitations of available resources, such as weight and power, and the impact of these limitations on the inspection technique are discussed, as well as the resultant impact on data analysis and processing algorithms. Of particular interest is the impact to the inspection technique resulting from the use of solar energy as a heat source, the effect on the measurements due to working in the vacuum of space, and the effect of changes in boundary conditions, such as radiation losses seen by the material, on the response of the RCC. The resultant effects on detectability limits are discussed. Keywords: Nondestructive Evaluation, Shuttle, on-orbit inspection, thermography, infrared

Howell, P. A.↗

NASA NTRS2004

NASA Thermographic Inspection of Advanced Composite Materials

As the use of advanced composite materials continues to increase in the aerospace community, the need for a quantitative, rapid, in situ inspection technology has become a critical concern throughout the industry. In many applications it is necessary to monitor changes in these materials over an extended period of time to determine the effects of various load conditions. Additionally, the detection and characterization of defects such as delaminations, is of great concern. This paper will present the application of infrared thermography to characterize various composite materials and show the advantages of different heat source types. Finally, various analysis methodologies used for quantitative material property characterization will be discussed.

Cramer, K. Elliott↗

NASA NTRS2003

Characterization of Effluents Given Off by Wiring Insulation

When an insulated wire is heated, the insulation emits a variety of effluents. This paper discusses the basis of emissions of effluents from wiring insulation. Several species are emitted at relatively low temperatures, while others are emitted when the wire reaches higher temperatures. We isolate the emissions by relative molecular weight of the effluents and measure the effluent concentration both as a function of time (temperature held constant) and by wire temperature. We find that the Law of Mass Action describes and predicts the time-dependence of the emission of a specific effluent caused by the heating. The binding energy is determined by performing an Arrhenius Plot on the temperature data. These dependencies are discussed and working equations are derived. Data collected from 20 gauge wire (MIL-W-22759/11-20) is used to illustrate and confirm the validity of the theory.

Yost, William T.↗

NASA NTRS2002

Thermal Nondestructive Evaluation Report: Inspection of the Refurbished Manipulator Arm System in the Manipulator Development Facility at Johnson Space Center 10-12 January 2001

On 4 December 2002, a failure of the Refurbished Manipulator Arm System (RMAS) occurred in the Manipulator Development Facility (MDF) at Johnson Space Center. When the Test Director commanded a should pitch maneuver to lift the arm from its payload bay pedestal, the yaw controls failed. This, coupled with a gravitational forces (due to the angle of the shoulder joint with respect to vertical), resulted in uncontrolled arm motion. The shoulder yaw joint moved approximately 20 degrees, causing the extended arm to strike and severely damage the port side MDF catwalk handrails. The arm motion stopped after impact with the handrails. On 10-12 January 2001, inspections were performed on the port face of the lower and upper arms of the RMAS using a infrared thermography developed at Langley Research Center. This paper presents the results of those nondestructive inspections and provides a complete description of the anomalies found and their locations.

Cramer, K. Elliott↗

NASA NTRS2001

Boiler Tube Corrosion Characterization with a Scanning Thermal Line

Wall thinning due to corrosion in utility boiler water wall tubing is a significant operational concern for boiler operators. Historically, conventional ultrasonics has been used for inspection of these tubes. Unfortunately, ultrasonic inspection is very manpower intense and slow. Therefore, thickness measurements are typically taken over a relatively small percentage of the total boiler wall and statistical analysis is used to determine the overall condition of the boiler tubing. Other inspection techniques, such as electromagnetic acoustic transducer (EMAT), have recently been evaluated, however they provide only a qualitative evaluation - identifying areas or spots where corrosion has significantly reduced the wall thickness. NASA Langley Research Center, in cooperation with ThermTech Services, has developed a thermal NDE technique designed to quantitatively measure the wall thickness and thus determine the amount of material thinning present in steel boiler tubing. The technique involves the movement of a thermal line source across the outer surface of the tubing followed by an infrared imager at a fixed distance behind the line source. Quantitative images of the material loss due to corrosion are reconstructed from measurements of the induced surface temperature variations. This paper will present a discussion of the development of the thermal imaging system as well as the techniques used to reconstruct images of flaws. The application of the thermal line source coupled with the analysis technique represents a significant improvement in the inspection speed and accuracy for large structures such as boiler water walls. A theoretical basis for the technique will be presented to establish the quantitative nature of the technique. Further, a dynamic calibration system will be presented for the technique that allows the extraction of thickness information from the temperature data. Additionally, the results of the application of this technology to actual water wall tubing samples and in-situ inspections will be presented.

Cramer, K. Elliott↗

NASA NTRS2000

Thermal Nondestructive Characterization of Corrosion in Boiler Tubes by Application fo a Moving Line Heat Source

Wall thinning in utility boiler waterwall tubing is a significant inspection concern for boiler operators. Historically, conventional ultrasonics has been used lor inspection of these tubes. This technique has proved to be very labor intensive and slow. This has resulted in a "spot check" approach to inspections, making thickness measurements over a relatively small percentage of the total boiler wall area. NASA Langley Research Center has developed a thermal NDE technique designed to image and quantitatively characterize the amount of material thinning present in steel tubing. The technique involves the movement of a thermal line source across the outer surface of the tubing followed by an infrared imager at a fixed distance behind the line source. Quantitative images of the material loss due to corrosion are reconstructed from measurements of the induced surface temperature variations. This paper will present a discussion of the development of the thermal imaging system as well as the techniques used to reconstruct images of flaws. The application of the thermal line source, coupled with this analysis technique, represents a significant improvement in the inspection speed for large structures such as boiler waterwalls while still providing high-resolution thickness measurements. A theoretical basis for the technique will be presented thus demonstrating the quantitative nature of the technique. Further, results of laboratory experiments on flat Panel specimens with fabricated material loss regions will be presented.

Cramer, K. Elliott↗

NASA NTRS2000

Thermographic Imaging of Material Loss in Boiler Water-Wall Tubing by Application of Scanning Line Source

Localized wall thinning due to corrosion in utility boiler water-wall tubing is a significant inspection concern for boiler operators. Historically, conventional ultrasonics has been used for inspection of these tubes. This technique has proven to be very manpower and time intensive. This has resulted in a spot check approach to inspections, documenting thickness measurements over a relatively small percentage of the total boiler wall area. NASA Langley Research Center has developed a thermal NDE technique designed to image and quantitatively characterize the amount of material thinning present in steel tubing. The technique involves the movement of a thermal line source across the outer surface of the tubing followed by an infrared imager at a fixed distance behind the line source. Quantitative images of the material loss due to corrosion are reconstructed from measurements of the induced surface temperature variations. This paper will present a discussion of the development of the thermal imaging system as well as the techniques used to reconstruct images of flaws. The application of the thermal line source coupled with the analysis technique represents a significant improvement in the inspection speed for large structures such as boiler water-walls. A theoretical basis for the technique will be presented which explains the quantitative nature of the technique. Further, a dynamic calibration system will be presented for the technique that allows the extraction of thickness information from the temperature data. Additionally, the results of applying this technology to actual water-wall tubing samples and in situ inspections will be presented.

Cramer, K. Elliott↗

NASA NTRS1999

Method and Apparatus for the Portable Identification of Material Thickness and Defects Using Spatially Controlled Heat Application

A method and a portable apparatus for the nondestructive identification of defects in structures. The apparatus comprises a heat source and a thermal imager that move at a constant speed past a test surface of a structure. The thermal imager is off set at a predetermined distance from the heat source. The heat source induces a constant surface temperature. The imager follows the heat source and produces a video image of the thermal characteristics of the test surface. Material defects produce deviations from the constant surface temperature that move at the inverse of the constant speed. Thermal noise produces deviations that move at random speed. Computer averaging of the digitized thermal image data with respect to the constant speed minimizes noise and improves the signal of valid defects. The motion of thermographic equipment coupled with the high signal to noise ratio render it suitable for portable, on site analysis.

Cramer, K. Elliott↗

NASA NTRS1998

Low-Cost Quality Control and Nondestructive Evaluation Technologies for General Aviation Structures

NASA's Advanced General Aviation Transport Experiments (AGATE) Program has as a goal to reduce the overall cost of producing private aviation aircraft while maintaining the safety of these aircraft. In order to successfully meet this goal, it is necessary to develop nondestructive inspection techniques which will facilitate the production of the materials used in these aircraft and assure the quality necessary to maintain airworthiness. This paper will discuss a particular class of general aviation materials and several nondestructive inspection techniques that have proven effective for making these inspections. Additionally, this paper will discuss the investigation and application of other commercially available quality control techniques applicable to these structures.

Cramer, K. Elliott↗