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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS1978

Inspection error and its adverse effects - A model with implications for practitioners

Inspection error has clearly been shown to have adverse effects upon the results desired from a quality assurance sampling plan. These effects upon performance measures have been well documented from a statistical point of view. However, little work has been presented to convince the QC manager of the unfavorable cost consequences resulting from inspection error. This paper develops a very general, yet easily used, mathematical cost model. The basic format of the well-known Guthrie-Johns model is used. However, it is modified as required to assess the effects of attributes sampling errors of the first and second kind. The economic results, under different yet realistic conditions, will no doubt be of interest to QC practitioners who face similar problems daily. Sampling inspection plans are optimized to minimize economic losses due to inspection error. Unfortunately, any error at all results in some economic loss which cannot be compensated for by sampling plan design; however, improvements over plans which neglect the presence of inspection error are possible. Implications for human performance betterment programs are apparent, as are trade-offs between sampling plan modification and inspection and training improvements economics.

Collins, R. D., Jr.↗
DOE OSTI2020

Y-12 Groundwater Protection Program Monitoring Well Inspection and Maintenance Plan

This plan describes the systematic approach for: inspecting the physical condition of monitoring wells at Y-12, determining maintenance needs that extend the life of a well, and identifying those wells that no longer meet acceptable monitoring well design or well construction standards and require plugging and abandonment. The inspection and maintenance of groundwater monitoring wells is one of the primary management strategies of the Y-12 Groundwater Protection Program (GWPP) Management Plan, that is, the “proactive stewardship of the extensive monitoring well network at Y-12" (Consolidated Nuclear Security, L.L.C. [CNS], 2018). Effective stewardship, and a program of routine inspections of the physical condition of each monitoring well, ensures that representative water-quality samples and hydrologic data are obtained from the well network and protects the subsurface environment. In accordance with the Y-12 GWPP Monitoring Optimization Plan (MOP) for Groundwater Monitoring Wells at the Y-12 National Security Complex, Oak Ridge, Tennessee (CNS, 2017), the status designation (active or inactive) for each well determines the scope and extent of well inspections and maintenance activities. This plan, in conjunction with the above document, formalizes the GWPP approach to focus available resources on monitoring wells which provide the most useful data, and for that reason the GWPP inspects and performs maintenance on the wells sampled by the GWPP. This plan applies to groundwater monitoring wells installed at Y-12 and the related waste management facilities located within the three hydrogeologic regimes: (1) the Bear Creek Hydrogeologic Regime (Bear Creek Regime), (2) the Upper East Fork Poplar Creek Hydrogeologic Regime (East Fork Regime), and (3) the Chestnut Ridge Hydrogeologic Regime (Chestnut Ridge Regime). The Bear Creek Regime encompasses the section of Bear Creek Valley (BCV) immediately west of Y-12. The East Fork Regime encompasses most of the Y-12 process, operations, and support facilities in BCV west of Scarboro Road. The Chestnut Ridge Regime is directly south of Y-12 and encompasses a section of Chestnut Ridge that is bounded to the west by a surface drainage feature (Dunaway Branch, located immediately west of Industrial Landfill II) and by Scarboro Road to the east. The GWPP maintains an extensive database of geographic and construction details and related information for the monitoring wells in each hydrogeologic regime in the Updated Subsurface Database for Bear Creek Valley, Chestnut Ridge, and Parts of Bethel Valley on the U.S. DOE Oak Ridge Reservation (CNS, 2019). A detailed description of the hydrogeologic framework at Y-12 can be found in the GWPP Management Plan (CNS, 2018).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Framework and Tool for Artificial Intelligence & Machine Learning (AI/ML) Enabled Automated Non-Destructive Inspection of Composites Aerostructures Manufacturing

Vehicles and systems in the field of aerospace have two major requirements: a high demand for a large quantity and an expectation to perform for their lifetime with little to no failures. Thus, there is a need for a fast production rate of aerospace products with high quality. Improvements to production rate have many benefits, including a reduction in energy consumption per unit manufactured. This would be from factory energy usage, which is required to build and verify a product. Manufacturing process specifications require inspection of parts to determine if any flaws are present. Depending on factory planning and product quality, especially at higher rates, the evaluation process can pose a production rate bottleneck. This project was comprised of using artificial intelligence and machine learning (AI/ML) methods on inspection evaluations with the objective of reducing the required time to produce an aerospace structure or product and without reducing the final quality.

42 ENGINEERING↗
NASA NTRS2014

ARES Biennial Report 2012 Final

Since the return of the first lunar samples, what is now the Astromaterials Research and Exploration Science (ARES) Directorate has had curatorial responsibility for all NASA-held extraterrestrial materials. Originating during the Apollo Program (1960s), this capability at Johnson Space Center (JSC) included scientists who were responsible for the science planning and training of astronauts for lunar surface activities as well as experts in the analysis and preservation of the precious returned samples. Today, ARES conducts research in basic and applied space and planetary science, and its scientific staff represents a broad diversity of expertise in the physical sciences (physics, chemistry, geology, astronomy), mathematics, and engineering organized into three offices (figure 1): Astromaterials Research (KR), Astromaterials Acquisition and Curation (KT), and Human Exploration Science (KX). Scientists within the Astromaterials Acquisition and Curation Office preserve, protect, document, and distribute samples of the current astromaterials collections. Since the return of the first lunar samples, ARES has been assigned curatorial responsibility for all NASA-held extraterrestrial materials (Apollo lunar samples, Antarctic meteorites - some of which have been confirmed to have originated on the Moon and on Mars - cosmic dust, solar wind samples, comet and interstellar dust particles, and space-exposed hardware). The responsibilities of curation consist not only of the longterm care of the samples, but also the support and planning for future sample collection missions and research and technology to enable new sample types. Curation provides the foundation for research into the samples. The Lunar Sample Facility and other curation clean rooms, the data center, laboratories, and associated instrumentation are unique NASA resources that, together with our staff's fundamental understanding of the entire collection, provide a service to the external research community, which relies on access to the samples. The curation efforts are greatly enhanced by a strong group of planetary scientists who conduct peerreviewed astromaterials research. Astromaterials Research Office scientists conduct peer-reviewed research as Principal or Co-Investigators in planetary science (e. g., cosmochemistry, origins of solar systems, Mars fundamental research, planetary geology and geophysics) and participate as Co-Investigators or Participating Scientists in many of NASA's robotic planetary missions. Since the last report, ARES has achieved several noteworthy milestones, some of which are documented in detail in the sections that follow. Within the Human Exploration Science Office, ARES is a world leader in orbital debris research, modeling and monitoring the debris environment, designing debris shielding, and developing policy to control and mitigate the orbital debris population. ARES has aggressively pursued refinements in knowledge of the debris environment and the hazard it presents to spacecraft. Additionally, the ARES Image Science and Analysis Group has been recognized as world class as a result of the high quality of near-real-time analysis of ascent and on-orbit inspection imagery to identify debris shedding, anomalies, and associated potential damage during Space Shuttle missions. ARES Earth scientists manage and continuously update the database of astronaut photography that is predominantly from Shuttle and ISS missions, but also includes the results of 40 years of human spaceflight. The Crew Earth Observations Web site (http://eol.jsc.nasa.gov/Education/ESS/crew.htm) continues to receive several million hits per month. ARES scientists are also influencing decisions in the development of the next generation of human and robotic spacecraft and missions through laboratory tests on the optical qualities of materials for windows, micrometeoroid/orbital debris shielding technology, and analog activities to assess surface science operations. ARES serves as host to numerous students and visiting scientists as part of the services provided to the research community and conducts a robust education and outreach program. ARES scientists are recognized nationally and internationally by virtue of their success in publishing in peer-reviewed journals and winning competitive research proposals. ARES scientists have won every major award presented by the Meteoritical Society, including the Leonard Medal, the most prestigious award in planetary science and cosmochemistry; the Barringer Medal, recognizing outstanding work in the field of impact cratering; the Nier Prize for outstanding research by a young scientist; and several recipients of the Nininger Meteorite Award. One of our scientists received the Department of Defense (DoD) Joint Meritorious Civilian Service Award (the highest civilian honor given by the DoD). ARES has established numerous partnerships with other NASA Centers, universities, and national laboratories. ARES scientists serve as journal editors, members of advisory panels and review committees, and society officers, and several scientists have been elected as Fellows in their professional societies. This biennial report summarizes a subset of the accomplishments made by each of the ARES offices and highlights participation in ongoing human and robotic missions, development of new missions, and planning for future human and robotic exploration of the solar system beyond low Earth orbit.

Stansbery, Eileen↗
DOE OSTI2020

Fabrication Lessons Learned of Transportation Packaging from the Perspective of a Design Authority - 20322

This paper presents lessons learned regarding fabricating packaging systems from the perspective of a design authority (DA). Capturing and implementing lessons learned is critical for an organization to reduce systematic project risk and thereby promote the likelihood of project success. This paper defines the design authority as the organization responsible for technical design, resolving technical design issues, quality assurance program, and maintenance of the packaging system license. A package system is defined as the packaging, its contents, and auxiliary equipment. Packages are certified by the NRC under 10 CFR 71[1] for transportation by ground. The following lessons learned subjects are presented in the paper: quality assurance, interpretation of drawing dimensional requirements, execution of manufacturing processes, hardware dimensional inspection, and leakage rate testing. All discrepancies presented in this paper have been resolved as described in the appropriate final data package. All described package systems are in compliance with their Safety Analysis Report (SAR) and certificate of conformance requirements. The intent of this paper is to identify opportunities for improving the outcome of future projects and to mitigate fabrication challenges proactively. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

PIP-II SRF Couplers Fabrication Status and Addressing Ceramic Yield Challenges

The PIP-II project requires reliable SRF couplers to deliver high RF power to the cavities. This talk presents the current status of coupler fabrication, including progress on procurement, assembly, and testing. In particular, it focuses on the challenges encountered with ceramic window production, where limited yield has become a concern. Observed issues and inspection results will be discussed, together with the actions taken to improve quality and consistency. The path forward, including ongoing work with vendors and process adjustments, will also be outlined.

Aiazzi, Tommaso [Fermilab] (ORCID:0009000297503407↗
NASA NTRS1974

Resin/graphite fiber composites

Techniques were developed that provided thermo-oxidatively stable A-type polyimide/graphite fiber composites using the approach of in situ polymerization of monomeric reactants directly on reinforcing fibers, rather than employing separately prepared prepolymer varnish. This was accomplished by simply mixing methylene dianiline and two ester-acids and applying this solution to the fibers for subsequent molding. Five different formulated molecular weight resins were examined, and an optimized die molding procedure established for the 1500 formulated molecular weight system. Extensive ultrasonic inspection of composites was successfully utilized as a technique for monitoring laminate quality. Composite mechanical property studies were conducted with this polyimide resin at room temperature and after various time exposures in a thermo-oxidative environment at 561 K (550 F), 589 K (600 F) and 617 K (650 F). It was determined that such composites have a long term life in the temperature range of 561 K to 589 K. The final phase involved the fabrication and evaluation of a series of demonstration airfoil specimens.

Cavano, P. J.↗
DOE OSTI2026

Machine Learning-Based Anomaly Detection for PMT Data Quality Monitoring in the SBN and DUNE

Maintaining high-quality detector data is essential for achieving the scientific objectives of the Short-Baseline Neutrino (SBN) Program at Fermilab. Current data quality monitoring (DQM) procedures rely primarily on threshold-based metrics and manual inspection of detector monitoring plots, making the detection of subtle or gradually developing anomalies both time-consuming and dependent on expert interpretation. This project developed and evaluated a machine-learning workflow for automatically identifying anomalous photomultiplier tube (PMT) channels in the Short-Baseline Near Detector (SBND) using optical-hit amplitude data. A Python-based analysis program was developed to process ROOT files, extract statistical features describing individual PMT amplitude distributions, and generate feature vectors for anomaly detection. These features were used to train an Isolation Forest model using data representing normal detector operation. The trained model was subsequently applied to independent detector runs to identify channels exhibiting statistically unusual behavior relative to the learned reference response. To support expert interpretation, the workflow generated complementary diagnostic products, including anomaly score distributions, normalized amplitude comparisons, decision-tree visualizations, and principal component analysis (PCA) projections. This project demonstrated the feasibility of integrating unsupervised machine learning into detector data-quality monitoring and developed a complete workflow for automated PMT performance assessment to aid expert-driven review. Beyond its technical contributions, the VFP appointment fostered a research collaboration between Aurora University and Fermilab and provided direct workforce development benefits by training the visiting faculty member in detector-scale machine-learning methods that are now being incorporated into undergraduate coursework and research. The methodology developed here provides a foundation for future applications to ProtoDUNE and other liquid argon time projection chamber (LArTPC) detectors, contributing to ongoing efforts to improve detector reliability, reduce manual monitoring requirements, and enable scalable data quality monitoring for future large-scale neutrino experiments, including the Deep Underground Neutrino Experiment (DUNE).

Colón Santana, Juan A. [Unlisted, US, IL]↗
NASA NTRS1998

Detection, Location, and Classification of Space Shuttle Main Engine Nozzle Leaks by Transient Thermographic Inspection

Leak checking and evaluation of pressure vessels by observing the slight temperature changes resulting from structural anomalies has been made possible through developments in high resolution infrared cameras and advanced image processing. These developments have made thermal nondestructive analysis a very practical and efficient method to determine material consistency and structural quality as well as monitor processes. The Space Shuttle Main Engine Nozzle has regions which can not be inspected with standard leak check methods. The Thermographic methods being developed to nondestructively test the Nozzle for leaks in inaccessible regions are reported. Also, a flash heating Thermographic investigation of the braze line bonding the cooling tubes to the outer structural jacket of the nozzle is reported.

Russell, Samuel S.↗
NASA NTRS2019

The Effect of Hole Quality on the Bearing Strength of Carbon Fiber Laminates

On programs involving flight hardware for launch vehicles that the author has been involved in over the years, the question always arises as to how to best machine and inspect holes drilled for fasteners. While common sense dictates that ‘well-drilled’ holes are desired over ‘poorly drilled’ holes for bolt bearing applications, the effect of hole quality on the bearing strength of carbon fiber laminates has not been extensively studied in the open literature. If this effect is not quantitatively known, the question of what hole quality needs to be required for the flight hardware cannot be answered. In addition, the function of the part with respect to the holes needs to be taken into account. There is no such thing as a defect-free hole since some chip-out of fibers within the hole will occur regardless of drill bit and backing plate pressure. For most holes machined in a carbon fiber laminate, some extent of delamination and fiber breakout on the entrance and exit of the hole is going to occur. Much time and money can be spent on trying to perfect the drilling technique and subsequent inspection of holes in carbon fiber laminates, including adding extra plies of cloth to the surfaces to help prevent fiber breakout; but is this effort really justified if little-to-no increase in bearing strength is realized by good-quality holes over those of lesser quality?

Nettles, A. T.↗
NASA NTRS1973

Nondestructive testing of electro thermal devices

This paper describes the results of a recent investigation into 'thermal time constant' nondestructive testing of high reliability electrical fuses. The use of established nondestructive test technology for examining the quality and firing characteristics of electro-explosive devices has been successfully applied to the inspection and prediction of the functional performance of electrical fuses. The technique requires application of a low level current pulse to the electrical fuse with an oscilloscope display of the curve as generated by the temperature coefficient of resistance feedback. The heating curve of temperature vs time is composed of one predominant thermal time constant, which is the product of the test unit's thermal capacity and thermal resistance. It has been found that the quality of the individual electrical fuse, for instance, the relative condition of the critical internal weld or solder joint, can be examined nondestructively.

Earnest, J. E., Jr.↗
NASA NTRS2021

Improving the CERES SYN Cloud and Flux Products by Identifying GOES-17 Scan Anomalies Using a Convolutional Neural Network

The NASA Clouds and the Earth’s Radiant Energy System (CERES) project relies on top-of-atmosphere (TOA) broadband fluxes derived from geostationary (GEO) satellite imagery to account for the diurnal flux variations between the CERES observation intervals, and thereby produce a synoptic gridded (SYN1deg) product based on continuous temporal observations. Consistent broadband flux derivation depends on accurate radiative property measurements and cloud retrievals, which largely determine the radiance-to-flux conversion process. Therefore, it is important to ensure a high quality of cloud property input in order to maintain a reliable broadband flux record. In Edition 4 of the CERES SYN1deg product, a robust automated image anomaly detection algorithm based on inter-line and inter-pixel differences, spatial variance, and 2-D Fourier analysis has been successful in identifying imagery with linear artifacts, but the line-by-line inspection and cleaning process must still be performed by a human. Therefore, further automation of this quality assurance process is warranted, especially considering the excessive amount of additional cleaning necessitated by the GOES-17 Advance Baseline Imager (ABI) cooling system anomaly. As such, this article highlights advancement of the CERES GEO image artifact cleaning approach based on a convolutional neural network (CNN) for classification of bad scanlines. Once trained, the CNN approach is a computationally inexpensive means to ensure greater consistency in cloud retrievals, and therefore broadband flux derivation, based on GOES-17 measurements.

Benjamin Scarino↗
NASA NTRS2000

Surface Fatigue Lives of Case-Carburized Gears With an Improved Surface Finish

Previous research provides qualitative evidence that an improved surface finish can increase the surface fatigue lives of gears. To quantify the influence of surface roughness on life, a set of AISI 93 10 steel gears was provided with a nearmirror finish by superfinishing. The effects of the superfinishing on the quality of the gear tooth surfaces were determined using data from metrology, profilometry, and interferometric microscope inspections. The superfinishing reduced the roughness average by about a factor of 5. The superfinished gears were subjected to surface fatigue testing at 1.71 -GPa (248-ksi) Hertz contact stress, and the data were compared with the NASA Glenn gear fatigue data base. The lives of gears with superfinished teeth were about four times greater compared with the lives of gears with ground teeth but with otherwise similar quality.

Krantz, T. L.↗
NASA NTRS1979

Quality assurance and control in the production and static tests of the solid rocket boosters for the Space Shuttle

The paper surveys the various aspects of design and overhaul of the solid rocket boosters. It is noted that quality control is an integral part of the design specifications. Attention is given to the production process which is optimized towards highest quality. Also discussed is the role of the DCA (Defense Contract Administration) in inspecting the products of subcontractors, noting that the USAF performs this role for prime contractors. Fabrication and construction of the booster is detailed with attention given to the lining of the booster cylinder and the mixing of the propellant and the subsequent X-ray inspection.

Cerny, O. F.↗
NASA NTRS1984

Trends of jet fuel demand and properties

Petroleum industry forecasts predict an increasing demand for jet fuels, a decrease in the gasoline-to-distillate (heavier fuel) demand ratio, and a greater influx of poorer quality petroleum in the next two to three decades. These projections are important for refinery product analyses. The forecasts have not been accurate, however, in predicting the recent, short term fluctuations in jet fuel and competing product demand. Changes in petroleum quality can be assessed, in part, by a review of jet fuel property inspections. Surveys covering the last 10 years show that average jet fuel freezing points, aromatic contents, and smoke points have trends toward their specification limits.

Friedman, R.↗
DOE OSTI2023

Deep Learning Based Workflow for Accelerated Industrial X-Ray Computed Tomography

X-ray computed tomography (XCT) is an important tool for high-resolution non-destructive characterization of additively-manufactured metal components. XCT reconstructions of metal components may have beam hardening artifacts such as cupping and streaking which makes reliable detection of flaws and defects challenging. Furthermore, traditional workflows based on using analytic reconstruction algorithms require a large number of projections for accurate characterization - leading to longer measurement times and hindering the adoption of XCT for in-line inspections. In this paper, we introduce a new workflow based on the use of two neural networks to obtain high-quality accelerated reconstructions from sparse-view XCT scans of single material metal parts. The first network, implemented using fully-connected layers, helps reduce the impact of BH in the projection data without the need of any calibration or knowledge of the component material. The second network, a convolutional neural network, maps a low-quality analytic 3D reconstruction to a high-quality reconstruction. Using experimental data, we demonstrate that our method robustly generalizes across several alloys, and for a range of sparsity levels without any need for retraining the networks thereby enabling accurate and fast industrial XCT inspections.

Rahman, Obaid↗
DOE OSTI2023

Binary pseudo-random array (BPRA) for inspection and calibration for cylindrical wavefront interferometry

High-accuracy metrology is vitally important in manufacturing ultra-high-quality free-form mirrors designed to manipulate X-ray light with nanometer-scale wavelengths. However, surface topography measurements are instrument dependent, and without the knowledge of how the instrument performs under the practical usage conditions, the measured data contain some degree of uncertainty. Binary Pseudo Random Array (BPRA) “white noise” artifact are effective and useful for characterizing the Instrument Transfer Function (ITF) of surface topography metrology tools and wavefront measurement instrument. BPRA artifact contains features with all spatial frequencies in the instrument bandpass with equal weight. As a result, power spectral density of the patterns has a deterministic white-noise-like character that allows direct determination of the ITF with uniform sensitivity over the entire spatial frequency range. The application examples include electron microscopes, x-ray microscopes, interferometric microscopes, and large field-of-view Fizeau Interferometers. Furthermore, we will introduce the application of BPRA method to characterizing the ITF of Cylindrical Wavefront Interferometry (CWI), by developing the BPRA artifact which matches the radius of curvature of the cylindrical wavefront. The data acquisition and analysis procedures for different applications of the ITF calibration technique developed are also discussed.

Munechika, K↗