Engineering topics

Martin, Richard E.

Publications and source records attributed to Martin, Richard E..

At least 37 records · Page 2

NASA NTRS2010

Evaluation of Ultrasonic and Thermal Nondestructive Evaluation for the Characterization of Aging Degradation in Braided Composite Materials

This paper examines the ability of traditional nondestructive evaluation (NDE) techniques to measure the degradation of braided polymer composite materials subjected to thermal-humidity cycling to simulate aging. A series of braided composite coupons were examined using immersion ultrasonic and pulsed thermography techniques in the as received condition. These same specimens were then examined following extended thermal-humidity cycling. Results of this examination did not show a significant change in the resulting (NDE) signals.

Martin, Richard E.↗

NASA NTRS2009

Mid-Infrared Reflectance Imaging of Thermal-Barrier Coatings

An apparatus for mid-infrared reflectance imaging has been developed as means of inspecting for subsurface damage in thermal-barrier coatings (TBCs). The apparatus is designed, more specifically, for imaging the progression of buried delamination cracks in plasma-sprayed yttria-stabilized zirconia coatings on turbine-engine components. Progression of TBC delamination occurs by the formation of buried cracks that grow and then link together to produce eventual TBC spallation. The mid-infrared reflectance imaging system described here makes it possible to see delamination progression that is invisible to the unaided eye, and therefore give sufficiently advanced warning before delamination progression adversely affects engine performance and safety. The apparatus (see figure) includes a commercial mid-infrared camera that contains a liquid-nitrogen-cooled focal plane indium antimonide photodetector array, and imaging is restricted by a narrow bandpass centered at wavelength of 4 microns. This narrow wavelength range centered at 4 microns was chosen because (1) it enables avoidance of interfering absorptions by atmospheric OH and CO2 at 3 and 4.25 microns, respectively; and (2) the coating material exhibits maximum transparency in this wavelength range. Delamination contrast is produced in the midinfrared reflectance images because the introduction of cracks into the TBC creates an internal TBC/air-gap interface with a high diffuse reflectivity of 0.81, resulting in substantially higher reflectance of mid-infrared radiation in regions that contain buried delamination cracks. The camera is positioned a short distance (.12 cm) from the specimen. The mid-infrared illumination is generated by a 50-watt silicon carbide source positioned to the side of the mid-infrared camera, and the illumination is collimated and reflected onto the specimen by a 6.35-cm-diameter off-axis paraboloidal mirror. Because the collected images are of a steady-state reflected intensity (in contrast to the transient thermal response observed in infrared thermography), collection times can be lengthened to whatever extent needed to achieve desired signal-to-noise ratios. Each image is digitized, and the resulting data are processed in several steps to obtain a true mid-infrared reflectance image. The raw image includes thermal radiation emitted by the specimen in addition to the desired reflected radiation. The thermal-radiation contribution is eliminated by subtracting the image obtained with the illumination off from the image obtained with the illumination on. A flat-field correction is then made to remove the effects of non-uniformities in the illumination level and pixel-to-pixel variations in sensitivity. This correction is performed by normalizing to an image of a standard object that has a known reflectance at a wavelength of 4 microns. After correction, each pixel value is proportional to the reflectance (at a wavelength of 4-microns) at the corresponding location on the specimen. Mid-infrared reflectance imaging of specimens that were thermally cyc led for different numbers of cycles was performed and demonstrated t hat mid-infrared reflectance imaging was able to monitor the gradual delamination progression that occurs with continued thermal cycling . Reproducible values were obtained for the reflectance associated w ith an attached and fully delaminated TBC, so that intermediate refle ctance values could be interpreted to successfully predict the numbe r of thermal cycles to failure.

Edlridge, Jeffrey I.↗

NASA NTRS2007

Fabrication and Characterization of Diffusion Bonds for Silicon Carbide

Diffusion bonds of silicon carbide (SiC) were fabricated using several different types of titanium (Ti) based interlayers between the SiC substrates. The interlayers were an alloyed Ti foil, a pure Ti foil, and a physically vapor deposited (PVD) Ti coating. Microscopy was conducted to evaluate the cross-sections of the resulting bonds. Microprobe analysis identified reaction formed phases in the diffusion bonded region. Uniform and well adhered bonds were formed between the SiC substrates. In the case where the alloyed Ti foil or a thick Ti coating (i.e. 20 micron) was used as the interlayer, microcracks and several phases were present in the diffusion bonds. When a thinner interlayer was used (i.e. 10 micron PVD Ti), no microcracks were observed and only two reaction formed phases were present. The two phases were preferred and fully reacted phases that did not introduce thermal stresses or microcracks during the cool-down stage after processing. Diffusion bonded samples were evaluated with the non-destructive evaluation (NDE) methods of pulsed thermography and immersion ultrasonic testing. Joined SiC substrates that were fully bonded and that had simulated bond flaws in the interlayer were also evaluated using immersion ultrasound. Pull testing was conducted on the bonds to determine the tensile strength. To demonstrate the joining approach for a complex multilayered component for a low NOx injector application, the diffusion bonding approach was used to join three 4" diameter SiC discs that contained complex fuel and air flow channels.

Halbig, Michael↗

NASA NTRS2007

A Software Platform for Post-Processing Waveform-Based NDE

Ultrasonic, microwave, and terahertz nondestructive evaluation imaging systems generally require the acquisition of waveforms at each scan point to form an image. For such systems, signal and image processing methods are commonly needed to extract information from the waves and improve resolution of, and highlight, defects in the image. Since some similarity exists for all waveform-based NDE methods, it would seem a common software platform containing multiple signal and image processing techniques to process the waveforms and images makes sense where multiple techniques, scientists, engineers, and organizations are involved. This presentation describes NASA Glenn Research Center's approach in developing a common software platform for processing waveform-based NDE signals and images. This platform is currently in use at NASA Glenn and at Lockheed Martin Michoud Assembly Facility for processing of pulsed terahertz and ultrasonic data. Highlights of the software operation will be given. A case study will be shown for use with terahertz data. The authors also request scientists and engineers who are interested in sharing customized signal and image processing algorithms to contribute to this effort by letting the authors code up and include these algorithms in future releases.

Roth, Donald J.↗

NASA NTRS2005

Vibration Based Crack Detection in a Rotating Disk: Experimental Results - Part 2

This paper describes the experimental results concerning the detection of a crack in a rotating disk. The goal was to utilize blade tip clearance and shaft vibration measurements to monitor changes in the system's center of mass and/or blade deformation behaviors. The concept of the approach is based on the fact that the development of a disk crack results in a distorted strain field within the component. As a result, a minute deformation in the disk's geometry as well as a change in the system's center of mass occurs. Here, a notch was used to simulate an actual crack. The vibration based experimental results failed to identify the existence of a notch when utilizing the approach described above, even with a rather large, circumferential notch (l.2 in.) located approximately mid-span on the disk (disk radius = 4.63 in. with notch at r = 2.12 in.). This was somewhat expected, since the finite element based results in Part 1 of this study predicted changes in blade tip clearance as well as center of mass shifts due to a notch to be less than 0.001 in. Therefore, the small changes incurred by the notch could not be differentiated from the mechanical and electrical noise of the rotor system. Although the crack detection technique of interest failed to identify the existence ofthe notch, the vibration data produced and captured here will be utilized in upcoming studies that will focus on different data mining techniques concerning damage detection in a disk.

Gyekenyesi, Andrew L.↗

NASA NTRS2005

Nondestructive Evaluation Tests Performed on Space Shuttle Leading- Edge Materials Subjected to Impact

In support of the space shuttle Return To Flight efforts at the NASA Glenn Research Center, a series of nondestructive evaluation (NDE) tests were performed on reinforced carbon/carbon (RCC) composite panels subjected to ballistic foam impact. The impact tests were conducted to refine and verify analytical models of an external tank foam strike on the space shuttle leading edge. The NDE tests were conducted to quantify the size and location of the resulting damage zone as well as to identify hidden damage.

Roth, Don J.↗

NASA NTRS2005

Ability of Impedance-Based Health Monitoring To Detect Structural Damage of Propulsion System Components Assessed

Impedance-based structural-health-monitoring uses piezoelectric (PZT) patches that are bonded onto or embedded in a structure. Each individual patch behaves as both an actuator of the surrounding structural area as well as a sensor of the structural response. The size of the excited area varies with the geometry and material composition of the structure, and an active patch is driven by a sinusoidal voltage sweep. When a PZT patch is subjected to an electric field, it produces a mechanical strain; and when it is stressed, it produces an electric charge. Since the patch is bonded to the structure, driving a patch deforms and vibrates the structure. The structure then produces a localized dynamic response. This structural system response is transferred back to the PZT patch, which in turn produces an electrical response. The electromechanical impedance method is based on the principle of electromechanical coupling between the active sensor and the structure, which allows researchers to assess local structural dynamics directly by interrogating a distributed sensor array. Because of mechanical coupling between the sensor and the host structure, this mechanical effect is picked up by the sensor and, through electromechanical coupling inside the active element, is reflected in electrical impedance measured at the sensor s terminals.

Martin, Richard E.↗

NASA NTRS2005

Ultrasonic Guided-Wave-Scan System Used to Characterize C-Enhanced Silicon Carbide Composite During Creep- Rupture Tests

Ceramic matrix composites (CMCs) are being developed for advanced aerospace propulsion applications in order to save weight, improve reuse capability, and increase performance. However, mechanical and environmental loads applied to CMCs can cause degradation in the form of discrete flaws and distributed microdamage that can play a significant role in reducing desirable physical properties. Categories of microdamage include fiber/matrix debonding (interface failure), matrix microcracking, fiber fracture and buckling, oxidation, and second-phase formation. Distributed microdamage in CMCs has proven difficult to characterize nondestructively because of the complex microstructure and macrostructure of these materials, and a recent study regarding the durability of a ceramic matrix composite discussed the requirement for improved nondestructive evaluation (NDE) methods for monitoring degradation in these materials.

Roth, Don J.↗

NASA NTRS2005

Damage Assessment of Aerospace Structural Components by Impedance Based Health Monitoring

This paper addresses recent efforts at the NASA Glenn Research Center at Lewis Field relating to the set-up and assessment of electro-mechanical (E/M) impedance based structural health monitoring. The overall aim is the application of the impedance based technique to aeronautic and space based structural components. As initial steps, a laboratory was created, software written, and experiments conducted on aluminum plates in undamaged and damaged states. A simulated crack, in the form of a narrow notch at various locations, was analyzed using piezoelectric-ceramic (PZT: lead, zirconate, titarate) patches as impedance measuring transducers. Descriptions of the impedance quantifying hardware and software are provided as well as experimental results. In summary, an impedance based health monitoring system was assembled and tested. The preliminary data showed that the impedance based technique was successful in recognizing the damage state of notched aluminum plates.

Gyekenyesi, Andrew L.↗

NASA NTRS2005

Nondestructive Evaluation of Thermal Barrier Coatings by Mid-infrared Reflectance

The application of mid-infrared reflectance (MIR) imaging to monitor damage in thermal barrier coatings (TBCs) has been extended from a previously demonstrated area-averaged spectroscopic analysis tool to become a practical imaging tool that provides the spatial resolution needed to quickly identify localized regions of TBC damage by visual inspection, Illumination optics and image collection procedures were developed to produce illumination-normalized flatfield reflectance images after subtraction of the background thermal emission. MIR reflectance images were collected with a bandpass filter centered at a wavelength of 4 microns, which provided the optimum balance between good sensitivity to buried cracks and coating erosion, but with a desirable sensitivity to TBC sintering and absorption from ambient gases. Examples are presented of the application of MIR reflectance imaging to monitor damage progression in plasma-sprayed 8wt% yttria-stabilized zirconia (8YSZ) TBCs subjected to either furnace cycling or alumina particle jet erosion. These results show that MIR reflectance imaging can reliably track the progression of buried delamination cracks produced by thermal cycling and can also be used to determine when any local section of the TBC has eroded beyond an acceptable limit. Modeling of the effects of buried cracks and erosion on reflectance will be presented to show the dependence of damage sensitivity to TBC thickness.

Eldridge, Jeffrey I↗

NASA NTRS2004

Characterization of C/Enhanced SiC Composite During Creep-Rupture Tests Using an Ultrasonic Guided Wave Scan System

An ultrasonic guided wave scan system was used to nondestructively monitor damage over time and position in a C/enhanced SiC sample that was creep tested to failure at 1200 C in air at a stress of 69 MPa (10 ksi). The use of the guided wave scan system for mapping evolving oxidation profiles (via porosity gradients resulting from oxidation) along the sample length and predicting failure location was explored. The creep-rupture tests were interrupted for ultrasonic evaluation every two hours until failure at approx. 17.5 cumulative hours.

Roth, Don J.↗

NASA NTRS2004

Automated Guided-Wave Scanning Developed to Characterize Materials and Detect Defects

The Nondestructive Evaluation (NDE) Group of the Optical Instrumentation Technology Branch at the NASA Glenn Research Center has developed a scanning system that uses guided waves to characterize materials and detect defects. The technique uses two ultrasonic transducers to interrogate the condition of a material. The sending transducer introduces an ultrasonic pulse at a point on the surface of the specimen, and the receiving transducer detects the signal after it has passed through the material. The aim of the method is to correlate certain parameters in both the time and frequency domains of the detected waveform to characteristics of the material between the two transducers. The scanning system is shown. The waveform parameters of interest include the attenuation due to internal damping, waveform shape parameters, and frequency shifts due to material changes. For the most part, guided waves are used to gauge the damage state and defect growth of materials subjected to various mechanical or environmental loads. The technique has been applied to polymer matrix composites, ceramic matrix composites, and metal matrix composites as well as metallic alloys. Historically, guided wave analysis has been a point-by-point, manual technique with waveforms collected at discrete locations and postprocessed. Data collection and analysis of this type limits the amount of detail that can be obtained. Also, the manual movement of the sensors is prone to user error and is time consuming. The development of an automated guided-wave scanning system has allowed the method to be applied to a wide variety of materials in a consistent, repeatable manner. Experimental studies have been conducted to determine the repeatability of the system as well as compare the results obtained using more traditional NDE methods. The following screen capture shows guided-wave scan results for a ceramic matrix composite plate, including images for each of nine calculated parameters. The system can display up to 18 different wave parameters. Multiple scans of the test specimen demonstrated excellent repeatability in the measurement of all the guided-wave parameters, far exceeding the traditional point-by-point technique. In addition, the scan was able to detect a subsurface defect that was confirmed using flash thermography This technology is being further refined to provide a more robust and efficient software environment. Future hardware upgrades will allow for multiple receiving transducers and the ability to scan more complex surfaces. This work supports composite materials development and testing under the Ultra-Efficient Engine Technology (UEET) Project, but it also will be applied to other material systems under development for a wide range of applications.

Martin, Richard E.↗

NASA NTRS2004

Vibration-Based Data Used to Detect Cracks in Rotating Disks

Rotor health monitoring and online damage detection are increasingly gaining the interest of aircraft engine manufacturers. This is primarily due to the fact that there is a necessity for improved safety during operation as well as a need for lower maintenance costs. Applied techniques for the damage detection and health monitoring of rotors are essential for engine safety, reliability, and life prediction. Recently, the United States set the ambitious goal of reducing the fatal accident rate for commercial aviation by 80 percent within 10 years. In turn, NASA, in collaboration with the Federal Aviation Administration, other Federal agencies, universities, and the airline and aircraft industries, responded by developing the Aviation Safety Program. This program provides research and technology products needed to help the aerospace industry achieve their aviation safety goal. The Nondestructive Evaluation (NDE) Group of the Optical Instrumentation Technology Branch at the NASA Glenn Research Center is currently developing propulsion-system-specific technologies to detect damage prior to catastrophe under the propulsion health management task. Currently, the NDE group is assessing the feasibility of utilizing real-time vibration data to detect cracks in turbine disks. The data are obtained from radial blade-tip clearance and shaft-clearance measurements made using capacitive or eddy-current probes. The concept is based on the fact that disk cracks distort the strain field within the component. This, in turn, causes a small deformation in the disk's geometry as well as a possible change in the system's center of mass. The geometric change and the center of mass shift can be indirectly characterized by monitoring the amplitude and phase of the first harmonic (i.e., the 1 component) of the vibration data. Spin pit experiments and full-scale engine tests have been conducted while monitoring for crack growth with this detection methodology. Even so, published data are extremely limited, and the basic foundation of the methodology has not been fully studied. The NDE group is working on developing this foundation on the basis of theoretical modeling as well as experimental data by using the newly constructed subscale spin system shown in the preceding photograph. This, in turn, involved designing an optimal sub-scale disk that was meant to represent a full-scale turbine disk; conducting finite element analyses of undamaged and damaged disks to define the disk's deformation and the resulting shift in center of mass; and creating a rotordynamic model of the complete disk and shaft assembly to confirm operation beyond the first critical concerning the subscale experimental setup. The finite element analysis data, defining the center of mass shift due to disk damage, are shown. As an example, the change in the center of mass for a disk spinning at 8000 rpm with a 0.963-in. notch was 1.3 x 10(exp -4) in. The actual vibration response of an undamaged disk as well as the theoretical response of a cracked disk is shown. Experiments with cracked disks are continuing, and new approaches for analyzing the captured vibration data are being developed to better detect damage in a rotor. In addition, the subscale spin system is being used to test the durability and sensitivity of new NDE sensors that focus on detecting localized damage. This is designed to supplement the global response of the crack-detection methodology described here.

Gyekenyesi, Andrew L.↗

NASA NTRS2004

Ultrasonic Guided-Wave Scan System Used to Characterize Microstructure and Defects in Ceramic Composites

Ceramic matrix composites (CMCs) are being developed for advanced aerospace propulsion applications to save weight, improve reuse capability, and increase performance. However, mechanical and environmental loads applied to CMCs can cause discrete flaws and distributed microdamage, significantly reducing desirable physical properties. Such microdamage includes fiber/matrix debonding (interface failure), matrix microcracking, fiber fracture and buckling, oxidation, and second phase formation. A recent study (ref. 1) of the durability of a C/SiC CMC discussed the requirement for improved nondestructive evaluation (NDE) methods for monitoring degradation in these materials. Distributed microdamage in CMCs has proven difficult to characterize nondestructively because of the complex microstructure and macrostructure of these materials. This year, an ultrasonic guided-wave scan system developed at the NASA Glenn Research Center was used to characterize various microstructural and flaw conditions in SiC/SiC (silicon carbide fiber in silicon carbide matrix) and C/SiC (carbon fiber in silicon carbide matrix) CMC samples.

Roth, Don J.↗

NASA NTRS2004

Effect of Surface Treatments on Electron Beam Freeform Fabricated Aluminum Structures

Electron beam freeform fabrication (EBF3) parts exhibit a ridged surface finish typical of many layer-additive processes. This, post-processing is required to produce a net shape with a smooth surface finish. High speed milling wire electrical discharge machining (EDM), electron beam glazing, and glass bead blasting were performed on EBF3-build 2219 aluminum alloy parts to reduce or eliminate the ridged surface features. Surface roughness, surface residual stress state, and microstructural characteristics were examined for each of the different surface treatment to assess the quality and effect of the surface treatments on the underlying material. The analysis evaluated the effectivenes of the different surface finishing techniques for achieving a smooth surface finish on an electron beam freeform fabricated part.

Taminger, Karen M. B.↗

NASA NTRS2004

Signal Processing Variables for Optimization of Flaw Detection in Composites Using Ultrasonic Guided Wave Scanning

This study analyzes the effect of signal processing variables on the ability of the ultrasonic guided wave scan method at NASA Glenn Research Center to distinguish various flaw conditions in ceramic matrix composites samples. In the ultrasonic guided wave scan method, several time- and frequency-domain parameters are calculated from the ultrasonic guided wave signal at each scan location to form images. The parameters include power spectral density, centroid mean time, total energy (zeroth moment), centroid frequency, and ultrasonic decay rate. A number of signal processing variables are available to the user when calculating these parameters. These signal processing variables include 1) the time portion of the time-domain waveform processed, 2) integration type for the properties requiring integrations, 3) bounded versus unbounded integrations, 4) power spectral density window type, 5) and the number of time segments chosen if using the short-time fourier transform to calculate ultrasonic decay rate. Flaw conditions examined included delamination, cracking, and density variation.

Roth, Don J.↗

NASA NTRS2003

Flaw Detection for Composite Materials Improved by Advanced Thermal Image Reconstruction Techniques

The development of advanced composite materials for use in space and propulsion components has seen considerable growth over the past few years. In addition to improvements that have been made in material properties and processing techniques, similar growth must be seen in the development of methods for the detection of flaws, either generated in service or during manufacturing. Thermal imaging techniques have proven to be successful for the nondestructive evaluation (NDE) of composite materials, but their detection capabilities decrease as flaw depth increases. The purpose of this research is to investigate advanced thermal imaging methods and thermal image processing technologies to increase the maximum depth below surface that a flaw can be detected and improve the contrast between flawed regions and sound regions.

Martin, Richard E.↗

NASA NTRS2003

High-Performance Acousto-Ultrasonic Scan System Being Developed

Acousto-ultrasonic (AU) interrogation is a single-sided nondestructive evaluation (NDE) technique employing separated sending and receiving transducers. It is used for assessing the microstructural condition and distributed damage state of the material between the transducers. AU is complementary to more traditional NDE methods, such as ultrasonic cscan, x-ray radiography, and thermographic inspection, which tend to be used primarily for discrete flaw detection. Throughout its history, AU has been used to inspect polymer matrix composites, metal matrix composites, ceramic matrix composites, and even monolithic metallic materials. The development of a high-performance automated AU scan system for characterizing within-sample microstructural and property homogeneity is currently in a prototype stage at NASA. This year, essential AU technology was reviewed. In addition, the basic hardware and software configuration for the scanner was developed, and preliminary results with the system were described. Mechanical and environmental loads applied to composite materials can cause distributed damage (as well as discrete defects) that plays a significant role in the degradation of physical properties. Such damage includes fiber/matrix debonding (interface failure), matrix microcracking, and fiber fracture and buckling. Investigations at the NASA Glenn Research Center have shown that traditional NDE scan inspection methods such as ultrasonic c-scan, x-ray imaging, and thermographic imaging tend to be more suited to discrete defect detection rather than the characterization of accumulated distributed micro-damage in composites. Since AU is focused on assessing the distributed micro-damage state of the material in between the sending and receiving transducers, it has proven to be quite suitable for assessing the relative composite material state. One major success story at Glenn with AU measurements has been the correlation between the ultrasonic decay rate obtained during AU inspection and the mechanical modulus (stiffness) seen during fatigue experiments with silicon carbide/silicon carbide (SiC/SiC) ceramic matrix composite samples. As shown in the figure, ultrasonic decay increased as the modulus decreased for the ceramic matrix composite tensile fatigue samples. The likely microstructural reason for the decrease in modulus (and increase in ultrasonic decay) is the matrix microcracking that commonly occurs during fatigue testing of these materials. Ultrasonic decay has shown the capability to track the pattern of transverse cracking and fiber breakage in these composites.

Roth, Don J.↗