SEARCH · Engineering Papers
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Repeatable nondestructive method prepares multilayer cryo-insulation material for thermal conductivity measurements. Data acquired are volume of boil-off gas, barometric pressure, gas temperature, chamber pressure, and differential pressure between extremities.
Polymers have been widely used as wiring electrical insulation materials in space/air-craft. The dielectric properties of insulation polymers can change over time, however, due to various aging processes such as exposure to heat, humidity and mechanical stress. Therefore, the study of polymers used in electrical insulation of wiring is important to the aerospace industry due to potential loss of life and aircraft in the event of an electrical fire caused by breakdown of wiring insulation. Part of this research is focused on studying the mechanisms of various environmental aging process of the polymers used in electrical wiring insulation and the ways in which their dielectric properties change as the material is subject to the aging processes. The other part of the project is to determine the feasibility of a new capacitive nondestructive testing method to indicate degradation in the wiring insulation, by measuring its permittivity.
Quantitative ultrasonic techniques are summarized with applications to the measurement of frequency-dependent attenuation and backscatter and to the NDE of composite laminates. Results are listed for the ultrasonic NDE of graphite-epoxy composite laminates including impact and fatigue damage as well as porosity. The methods reviewed include transmission measurements of attenuation, reconstructive tomography based on attenuation, estimating attenuation from backscattered ultrasound, and backscatter approaches. Phase-sensitive and -insensitive detection techniques are mentioned such as phase cancellation at piezoelectric receiving transducers and acoustoelectric effects. The techniques permit the NDE of the parameters listed in inhomogeneous media and provide both images from the transmission mode and in the reflection mode.
The increased use of high-temperature composite materials in modern and next generation aircraft and spacecraft have led to the need for improved nondestructive evaluation and health monitoring techniques. Such technologies are desirable to improve quality control, damage detection, stress evaluation and temperature measurement capabilities. Novel eddy current sensors and sensor arrays, such as Meandering Winding Magnetometers (MWMs) have provided alternate or complimentary techniques to ultrasound and thermography for both nondestructive evaluation (NDE) and structural health monitoring (SHM). This includes imaging of composite material quality, damage detection and .the monitoring of fiber temperatures and multidirectional stresses. Historically, implementation of MWM technology for the inspection of the Space Shuttle Orbiter Reinforced Carbon-Carbon Composite (RCC) leading edge panels was developed by JENTEK Sensors and was subsequently transitioned by NASA as an operational pre and post flight in-situ inspection at the Kennedy Space Center. A manual scanner, which conformed'automatically to the curvature of the RCC panels was developed and used as a secondary technique if a defect was found during an infrared thermography screening, During a recent proof of concept study on composite overwrapped pressure vessels (COPV's), three different MWM sensors were tested at three orientations to demonstrate the ability of the technology to measure stresses at various fiber orientations and depths. These results showed excellent correlation with actual surface strain gage measurements. Recent advancements of this technology have been made applying MWM sensor technology for scanning COPVs for mechanical damage. This presentation will outline the recent advance~ in the MWM.technology and the development of MWM techniques for NDE and SHM of carbon wra~ped composite overwrapped pressure vessels (COPVs) including the measurement of internal stresses via a surface mounted sensor array. In addition, this paper will outline recent efforts to produce sensors capable of making real-time measurements at temperatures up to 850 C, and discuss previous results demonstrating capability to monitor carbon fiber temperature changes within a composite material.
Critical technology experiments have been performed on thermal energy storage modules in support of the Brayton Advanced Heat Receiver program. The modules are wedge-shaped canisters designed to minimize the mechanical stresses that occur during the phase change of the lithium fluoride phase change material. Nickel foam inserts were used in some of the canisters to provide thermal conductivity enhancement and to distribute the void volume. Two canisters, one with a nickel foam insert, and one without, were thermally cycled in various orientations in a fluidized bed furnace. The only measurable impact of the nickel foam was seen when the back and short sides of the canister were insulated to simulate operation in the advanced receiver design. In tests with insulation, the furnace to back side delta T was larger in the canister with the nickel foam insert, probably due to the radiant absorptivity of the nickel. However, the differences in the temperature profiles of the two canisters were small, and in many cases the profiles matched fairly well. Computed Tomography (CT) was successfully used to nondestructively demarcate void locations in the canisters. Finally, canister dimensional stability, which was measured throughout the thermal cycling test program with an inspection fixture was satisfactory with a maximum change of 0.635 mm (0.025 in.).
To date, very little is understood about electrotransport in thin films. One reason for this is the lack of methods in which electromigration can be adequately monitored dynamically. In this thesis, a new nondestructive method for the study of the electrotransport phenomenon in thin aluminum films is presented. This method makes use of electrical resistance measurements of various regions along the test sample to monitor changes in resistance resulting from electromigration. The advantage of this method is that resistance changes can be observed long before void formation can be seen using standard microscopy methods. In order to achieve the best efficiency using this method, special consideration must be given to the design of the sample. Design problems and their respective solutions are given. The results of the electrical resistance measurements are interpreted by means of photographs taken with an scanning electron microscope. The increase in resistance of the aluminum samples is interpreted to be due to void formation. The expected decrease in resistance near the anode was never observed. It is shown that mass accumulation takes on the form of hillocks and whiskers on the surface of the aluminum film, which does not contribute appreciably to conductivity.
A common method of determining elastic material properties is utilizing an ultrasonic pulse receiver. This is a non-destructive test (NDT) causing no plastic deformation of the material. It requires a pulse generator, oscilloscope, and two transducers to measure the sound velocity of a material. Both longitudinal and shear sound velocities may be obtained by utilizing the appropriate transducer. Acoustic nondestructive testing methods are often used in manufacturing certification processes and for material defect detection in industry. These methods can also be utilized to directly measure the elastic moduli of a material without damaging the material. Overall, it is a low-cost experiment with minimal preparation, and is easy to use.
High-energy photon interrogation is a nondestructive technique that is used to detect special nuclear materials and characterize nuclear waste. The development of such systems is complex and requires Monte Carlo simulations to optimize system performance. Monte Carlo simulations rely on various scattering, absorption, and photonuclear cross-section data. While the scattering and absorption cross-section data have been extensively studied and validated with experiments, the results obtained from photonuclear simulations are often found to underpredict measured results, indicating uncertainties in the photonuclear cross sections themselves. Thus, there is a need for new measured results that can be used to quantify underpredictions in simulations using photonuclear cross-section data. In the present work, we interrogated depleted uranium with a 9-MV electron linac and detected photoneutrons with trans-stilbene organic scintillators. The measurement of photoneutrons with organic scintillators is challenging due to the presence of the intense photon flux, which causes issues such as pulse pile-up, detector saturation, and poor signal-to-background ratio. To mitigate these challenges, we used iron and polyethylene shielding of varying thicknesses around the depleted uranium target and a neural network–based digital pulse processing algorithm to recover neutron and photon information from piled-up events. Our goal was to compare the measured photoneutron count rate with the simulated rate obtained using the MCNPX-PoliMi transport code. For a light output window of 0.28 to 2.67 MeVee (1.66- to 6.85-MeV proton recoil energy), we found that the simulated count rate obtained using the ENDF/B-VII photonuclear cross-section library underpredicts the measured rate by 32.8% 3.2%. Additionally, we compared the simulated and measured photoneutron light output distributions. For the least thicknesses of shielding, the simulation was found to underpredict measurements in the 0.70- to 2.67-MeVee light output window. For the greatest thicknesses of shielding, the simulation was found to underpredict the measurement across the entire light output window of 0.28 to 2.67 MeVee.
Monolithic ceramic materials have been used in industry for hundreds of years. These materials have proven their usefulness in many applications, yet, their potential for critical structural applications is limited. The existence of an imperfection in a monolithic ceramic on the order of several microns in size may be critical, resulting in catastrophic failure. To overcome this extreme sensitivity to small material imperfections, reinforced ceramic materials were developed. A ceramic matrix which has been reinforced with continuous fibers is not only less sensitive to microscopic flaws, but is also able to sustain significant damage without suffering catastrophic failure. A borosilicate glass reinforced with several layers of plain weave silicon carbide cloth (Nicalon) was studied. The mechanical testing which was performed included both flexural and tensile loading configurations. This testing was done not only to determine the material properties, but also to initiate a controlled amount of damage within each specimen. Several nondestructive testing techniques, including acousto-ultrasonics (AU), were performed on the specimens periodically during testing. The AU signals were monitored through the use of an IBM compatible personal computer with a high speed data acquisition board. Software was written which manipulates the AU signals in both the time and frequency domains, resulting in quantitative measures of the mechanical response of the material. The measured AU parameters are compared to both the mechanical test results and data from other nondestructive methods including ultrasonic C-scans and penetrant enhanced x ray radiography.
The purpose of this dissertation was the following: (1) to characterize the effect of pore fraction on a comprehensive set of electrical and magnetic properties for the yttrium-barium-copper-oxide (YBCO) high temperature ceramic superconductor; and (2) to determine the viability of using a room-temperature, nondestructive characterization method to aid in the prediction of superconducting (cryogenic) properties. The latter involved correlating ultrasonic velocity measurements at room temperature with property-affecting pore fraction and oxygen content variations. The use of ultrasonic velocity for estimating pore fraction in YBCO is presented, and other polycrystalline materials are reviewed, modeled, and statistically analyzed. This provides the basis for using ultrasonic velocity to interrogate microstructure. The effect of pore fraction (0.10-0.25) on superconductor properties of YBCO samples was characterized. Spatial (within-sample) variations in microstructure and superconductor properties were investigated, and the effect of oxygen content on elastic behavior was examined. Experimental methods used included a.c. susceptibility, electrical, and ultrasonic velocity measurements. Superconductor properties measured included transition temperature, magnetic transition width, transport and magnetic critical current density, magnetic shielding, a.c. loss, and sharpness of the voltage-current characteristics. An ultrasonic velocity image constructed from measurements at 1mm increments across a YBCO sample revealed microstructural variations that correlated with variations in magnetic shielding and a.c. loss behavior. Destructive examination using quantitative image analysis revealed pore fraction to be the varying microstructural feature.
An integral part of any sample return mission is the initial description and classification of returned samples by the preliminary examination team (PET). The goal of the PET is to characterize and classify returned samples and make this information available to the larger research community who then conduct more in-depth studies on the samples. The PET tries to minimize the impact their work has on the sample suite, which has in the past limited the PET work to largely visual, nonquantitative measurements (e.g., optical microscopy). More modern techniques can also be utilized by a PET to nondestructively characterize astromaterials in much more rigorous way. Here we discuss our recent investigations into the applications of micro-CT and micro-XRF analyses with Apollo samples and ANSMET meteorites and assess the usefulness of these techniques in future PET. Results: The application of micro computerized tomography (micro-CT) to astromaterials is not a new concept. The technique involves scanning samples with high-energy x-rays and constructing 3-dimensional images of the density of materials within the sample. The technique can routinely measure large samples (up to approx. 2700 cu cm) with a small individual voxel size (approx. 30 cu m), and has the sensitivity to distinguish the major rock forming minerals and identify clast populations within brecciated samples. We have recently run a test sample of a terrestrial breccia with a carbonate matrix and multiple igneous clast lithologies. The test results are promising and we will soon analyze a approx. 600 g piece of Apollo sample 14321 to map out the clast population within the sample. Benchtop micro x-ray fluorescence (micro-XRF) instruments can rapidly scan large areas (approx. 100 sq cm) with a small pixel size (approx. 25 microns) and measure the (semi) quantitative composition of largely unprepared surfaces for all elements between Be and U, often with sensitivity on the order of a approx. 100 ppm. Our recent testing of meteorite and Apollo samples on micro-XRF instruments has shown that they can easily detect small zircons and phosphates (approx. 10 m), distinguish different clast lithologies within breccias, and identify different lithologies within small rock fragments (2-4 mm soil Apollo soil fragments).
A system and methodology were developed for the nondestructive qualitative and quantitative analysis of volatile emissions from hydroponically grown 'Waldmann's Green' leaf lettuce (Lactuca sativa L.). Photosynthetic photon flux (PPF), photoperiod, and temperature were automatically controlled and monitored in a growth chamber modified for the collection of plant volatiles. The lipoxygenase pathway products (Z)-3-hexenal, (Z)-3-hexenol, and (Z)-3-hexenyl acetate were emitted by lettuce plants after the transition from the light period to the dark period. The volatile collection system developed in this study enabled measurements of volatiles emitted by intact plants, from planting to harvest, under controlled environmental conditions.
X-radiographic penetrant, ultrasonic, eddy current, holographic, and acoustic emission techniques were optimized and applied to the evaluation of 2219-T87 aluminum alloy test specimens. One hundred eighteen specimens containing a total of 328 fatigue cracks were evaluated. The cracks ranged in length from 0.500 inch (1.27 cm) to 0.007 inch (0.018 cm) and in depth from 0.178 inch (0.451 cm) and 0.001 inch (0.003 cm). Specimen thicknesses were nominally 0.060 inch (0.152 cm) and 0.210 inch (0.532 cm) and surface finishes were nominally 32 and 125 rms and 64 and 200 rms respectively. Specimens were evaluated in the as-milled surface condition, in the chemically milled surface condition and, after proof loading, in a randomized inspection sequence. Results of the nondestructive test (NDT) evaluations were compared with actual crack size obtained by measurement of the fractured specimens. Inspection data was then analyzed to provide a statistical basis for determinating the threshold crack detection sensitivity (the largest crack size that would be missed) for each of the inspection techniques at a 95% probability and 95% confidence level.
Liquid penetrant, ultrasonic, eddy current and X-radiographic techniques were optimized and applied to the evaluation of 2219-T87 aluminum alloy test specimens in integrally stiffened panel, and weld panel configurations. Fatigue cracks in integrally stiffened panels, lack-of-fusion in weld panels, and fatigue cracks in weld panels were the flaw types used for evaluation. A 2319 aluminum alloy weld filler rod was used for all welding to produce the test specimens. Forty seven integrally stiffened panels containing a total of 146 fatigue cracks, ninety three lack-of-penetration (LOP) specimens containing a total of 239 LOP flaws, and one-hundred seventeen welded specimens containing a total of 293 fatigue cracks were evaluated. Nondestructive test detection reliability enhancement was evaluated during separate inspection sequences in the specimens in the 'as-machined or as-welded', post etched and post proof loaded conditions. Results of the nondestructive test evaluations were compared to the actual flaw size obtained by measurement of the fracture specimens after completing all inspection sequences. Inspection data were then analyzed to provide a statistical basis for determining the flaw detection reliability.
Characteristics of wave propagation in an undamaged composite medium are influenced by many factors, the most important of which are: microstructure, constituent properties, interfaces, residual stress fields, and ply lay-ups. Measurements of wave velocities, attenuation, and dispersion provide a powerful tool for nondestructive evaluation of these properties. Recent developments are reviewed for modeling ultrasonic wave propagation in fiber and particle-reinforced composite media. Additionally, some modeling studies are reviewed for the effects of interfaces and layering on attenuation and dispersion. These studies indicate possible ways of characterizing material properties by ultrasonic means.
Critical technology experiments have been performed on thermal energy storage modules in support of the NASA Advanced Solar Dynamic Brayton Heat Receiver Program. The modules, wedge-shaped canisters containing lithium fluoride (LiF), were designed to minimize the mechanical stresses that occur during the phase change of the LiF. Nickel foam inserts were placed in two of the test canisters to provide thermal conductivity enhancement and to distribute the void volume throughout the canister. A procedure was developed for reducing the nickel oxides on the nickel foam to enhance the wicking ability of the foam. The canisters were filled with LiF and closure-welded at the NASA Lewis Research Center. Two canisters, one with a nickel foam insert, the other without an insert, were thermally cycled in various orientations in a fluidized bed furnace. Computer-aided tomography was successfully used to nondestructively determine void locations in the canisters. Finally, canister dimensional stability was measured after thermal cycling with an inspection fixture.
Real time nondestructive evaluation is required for composites load testing. The early detection and measurement of damage progression is important to understand failure modes. A single stringer panel was subjected to quasi-static loading to induce deformation which can result in the formation of delamination damage between the stiffener flange and skin. Passive thermography was used to detect damage in real time as a function of the applied load. The loading was stopped when damage growth was detected. Of particular interest was the early detection of damage formation which can be challenging, as compared to cyclic fatigue loading. Passive thermography data were acquired and processed in real time and revealed damaged areas due to heating from fiber breakage and delamination formation. The processed thermal imagery was also compared to acoustic emission and ultrasound data.
The Nondestructive Assay Program (NDAP) mission and vision is achieved by identifying and accomplishing a set of programmatic goals that correspond with eight broad technical program elements. The NDAP was created as a result of Defense Nuclear Facility Safety Board Recommendation 2007-1, entitled “Safety-Related In Situ Nondestructive Assay of Radioactive Materials,” which emphasized the need to improve in situ measurements of radioactive material at US Department of Energy (DOE) defense nuclear facilities. An NDAP five-year plan will define tasks to accomplish specific goals identified in the NDAP mission and vision. This mission and vision is applicable for eight technical program elements: Hardware/Software Development, Algorithm Development and Nuclear Data, Uncertainty Quantification, Nuclear Materials, Staffing, Personnel, And Training, Data Management, Requirement and Standards, and Information Preservation and Dissemination. An additional program element is technical support, which provides daily execution management support for the NDAP, site scope, and deliverable tracking via site task managers, along with technical advisement and support from the technical support group. The NDAP mission and vision provides attributes with specific goals for each program element, and some goals benefit multiple program elements. The goals and attributes defined herein are implemented via an NDAP five-year execution plan that defines site work scope, budget, and deliverables, all of which are updated annually. The NDAP is designed to benefit nondestructive assay (NDA) needs to support DOE nuclear criticality safety programs, ensuring that NDA technology is sufficiently capable of guaranteeing the safety of those who handle, store, process, or transport fissionable materials in the complex. Especially important for the NDAP is to maximize capabilities to identify, characterize, and manage in situ fissile material deposits in process equipment to ensure nuclear criticality safety at processing facilities.