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At least 271 records · Page 15

Automated Counting of Particles To Quantify Cleanliness

A machine vision system, similar to systems used in microbiological laboratories to count cultured microbes, has been proposed for quantifying the cleanliness of nominally precisely cleaned hardware by counting residual contaminant particles. The system would include a microscope equipped with an electronic camera and circuitry to digitize the camera output, a personal computer programmed with machine-vision and interface software, and digital storage media. A filter pad, through which had been aspirated solvent from rinsing the hardware in question, would be placed on the microscope stage. A high-resolution image of the filter pad would be recorded. The computer would analyze the image and present a histogram of sizes of particles on the filter. On the basis of the histogram and a measure of the desired level of cleanliness, the hardware would be accepted or rejected. If the hardware were accepted, the image would be saved, along with other information, as a quality record. If the hardware were rejected, the histogram and ancillary information would be recorded for analysis of trends. The software would perceive particles that are too large or too numerous to meet a specified particle-distribution profile. Anomalous particles or fibrous material would be flagged for inspection.

Rhode, James↗

SpaceX Dragon 1 Post Flight MMOD Inspection Campaign

Introduction The SpaceX Dragon 1 spacecraft performed 20 resupply missions to the International Space Station (ISS) between 2012 and 2020. After each mission, a team from the NASA John-son Space Center Hypervelocity Impact Technology Group inspected each Dragon 1 capsule for hypervelocity impact damage features. Data from these inspections are collected into a database that includes impact feature dimensions as well as the location on the vehicle. Additional details on the type and size of particle that produced the damage site are provided when sampling data and definitive spectroscopic analysis results are available. Observation data can be compared with impact estimates from risk assessment codes as a check on the micrometeoroid and orbital debris (MMOD) environment predictions. Scope A general description of the areas of the vehicle that were inspected are provided as well as mission details such as exposure duration and launch dates. The paper documents the general inspection procedure for collection of data and the post inspection data analysis process. It also provides details of the observation data collected as well as the results of analysis of intact samples collected for spectroscopic analysis to discern the source of the impacting particle. A comparison between observed impacts and the expected number of damage features calculated by Bumper 3 with the latest MMOD environments are also presented. Findings Statistics on the >300 impact features documented in the database will provide insight into the depth to diameter ratios and other relationships. The quality of the comparison between the observations and code predictions are dependent on several factors. The paper provides de-tails of each of these variables. (1) Damage equations (2) Impact condition assumptions a. Projectile density b. Impact speed c. Impact angle (3) Analysis results a. pre-flight vs. on-orbit damage b. MMOD vs. non-MMOD Conclusions and Recommendations The ISS visiting vehicle impact database is an ongoing project. SpaceX provides crew rotations as well as resupply and cargo return with the Dragon 2 spacecraft. Sierra Space is manifested for resupply and cargo return services starting in 2023. Boeing is expected to provide crew rotations as well. All of these spacecraft will provide additional opportunities for post flight MMOD inspections of space exposed hardware. Acknowledgements Over the course of the inspection campaign various personnel at the SpaceX Texas Test Site in McGregor and at the SpaceX headquarters in Hawthorne CA provided valuable support to this activity.

James L Hyde↗

Results of shuttle EMU thermal vacuum tests incorporating an infrared imaging camera data acquisition system

Manned tests in Chamber B at NASA JSC were conducted in May and June of 1990 to better quantify the Space Shuttle Extravehicular Mobility Unit's (EMU) thermal performance in the cold environmental extremes of space. Use of an infrared imaging camera with real-time video monitoring of the output significantly added to the scope, quality and interpretation of the test conduct and data acquisition. Results of this test program have been effective in the thermal certification of a new insulation configuration and the '5000 Series' glove. In addition, the acceptable thermal performance of flight garments with visually deteriorated insulation was successfully demonstrated, thereby saving significant inspection and garment replacement cost. This test program also established a new method for collecting data vital to improving crew thermal comfort in a cold environment.

Anderson, James E.↗

Ultrasonic Inspection With Angular-Power-Spectrum Scanning

Principal advantage of angular-power-spectrum scanning (APSS) is that, unlike x-radiography and prior ultrasonic techniques, it reveals subtle distributions of microstructural features; e.g., variations in densities of micropores or regions in which fibers and matrices are poorly bonded to each other. Potential applications include development and characterization of composite-material components of large structures, such as buildings and bridges; determination of quality and detection of damage in fiberglass hulls, surfboards, ladders, and scaffolds; and development of porous prosthetic skins and complicated "smart" materials. Superposed diffraction patterns give clues to internal structural features of ceramic composites.

Generazio, Edward R.↗

Mach 6 electroformed nickel nozzle refurbishment: FNAS investigation of ultra-smooth surfaces

The task objective has been to apply a coating of nickel-phosphorous alloy to a laminar flow wind tunnel nozzle by catalytic deposition and then polish and inspect the inside surface using optical device processes. The surface of the nozzle was coated with a nickel-phosphorous alloy of sufficient hardness and corrosion resistance to improve the durability. Due to plating defects that were clearly process related and not inherent, the final polished part was less than the desired quality. Surface finishing processes and lapping media were identified which produced a submicron surface finish on the interior plated surface. Defects apparently manifested by the first plating attempt were repaired using a small brush plating process demonstrating that individual small defects can be repaired. Measurement and analysis by profilometry demonstrated that quantitative control of the surface can be achieved.

Rood, Robert↗

Eddy-Current Inspection Of Tab Seals On Beverage Cans

Eddy-current inspection system monitors tab seals on beverage cans. Device inspects all cans at usual production rate of 1,500 to 2,000 cans per minute. Automated inspection of all units replaces visual inspection by microscope aided by mass spectrometry. System detects defects in real time. Sealed cans on conveyor pass near one of two coils in differential eddy-current probe. Other coil in differential eddy-current probe positioned near stationary reference can on which tab seal is known to be of acceptable quality. Signal of certain magnitude at output of probe indicates defective can, automatically ejected from conveyor.

Bar-Cohen, Yoseph↗

Should Pruning be a Pre-Processor of any Linear System?

There are many real-world problems whose mathematical models turn out to be linear systems Ax = b , where A is an m by x n matrix. Each equation of the linear system is an information. An information, in a physical problem, such as 4 mangoes, 6 bananas, and 5 oranges cost $10, is mathematically modeled as 4x(sub 1) + 6x(sub 2) + 5x (sub 3) = 10, where x(sub 1), x(sub 2), x(sub 3) are each cost of one mango, that of one banana, and that of one orange, respectively. All the information put together in a specified context, constitutes the physical problem and need not be all distinct. Some of these could be redundant, which cannot be readily identified by inspection. The resulting mathematical model will thus have equations corresponding to this redundant information and hence are linearly dependent and thus superfluous. Consequently, these equations once identified should be better pruned in the process of solving the system. The benefits are (i) less computation and hence less error and consequently a better quality of solution and (ii) reduced storage requirements. In literature, the pruning concept is not in vogue so far although it is most desirable. In a numerical linear system, the system could be slightly inconsistent or inconsistent of varying degree. If the system is too inconsistent, then we should fall back on to the physical problem (PP), check the correctness of the PP derived from the material universe, modify it, if necessary, and then check the corresponding mathematical model (MM) and correct it. In nature/material universe, inconsistency is completely nonexistent. If the MM becomes inconsistent, it could be due to error introduced by the concerned measuring device and/or due to assumptions made on the PP to obtain an MM which is relatively easily solvable or simply due to human error. No measuring device can usually measure a quantity with an accuracy greater that 0.005% or, equivalently with a relative error less than 0.005%. Hence measurement error is unavoidable in a numerical linear system when the quantities are continuous (or even discrete with extremely large number). Assumptions, though not desirable, are usually made when we find the problem sufficiently difficult to be solved within the available means/tools/resources and hence distort the PP and the corresponding MM. The error thus introduced in the system could (not always necessarily though) make the system somewhat inconsistent. If the inconsistency (contradiction) is too much then one should definitely not proceed to solve the system in terms of getting a least-squares solution or a minimum norm solution or the minimum-norm least-squares solution. All these solutions will be invariably of no real-world use. If, on the other hand, inconsistency is reasonably low, i.e. the system is near-consistent or, equivalently, has near-linearly-dependent rows, then the foregoing solutions are useful. Pruning in such a near-consistent system should be performed based on the desired accuracy and on the definition of near-linear dependence. In this article, we discuss pruning over various kinds of linear systems and strongly suggest its use as a pre-processor or as a part of an algorithm. Ideally pruning should (i) be a part of the solution process (algorithm) of the system, (ii) reduce both computational error and complexity of the process, and (iii) take into account the numerical zero defined in the context. These are precisely what we achieve through our proposed O(mn2) algorithm presented in Matlab, that uses a subprogram of solving a single linear equation and that has embedded in it the pruning.

Sen, Syamal K.↗

Should Pruning be a Pre-Processor of any Linear System?

There are many real-world problems whose mathematical models turn out to be linear systems Ax = b, where A is an m x n matrix. Each equation of the linear system is an information. An information, in a physical problem, such as 4 mangoes, 6 bananas, and 5 oranges cost $10, is mathematically modeled as an equation 4x(sub 1) + 6x(sub 2) + 5x(sub 3) = 10 , where x(sub 1), x(sub 2), x(sub 3) are each cost of one mango, that of one banana, and that of one orange, respectively. All the information put together in a specified context, constitutes the physical problem and need not be all distinct. Some of these could be redundant, which cannot be readily identified by inspection. The resulting mathematical model will thus have equations corresponding to this redundant information and hence are linearly dependent and thus superfluous. Consequently, these equations once identified should be better pruned in the process of solving the system. The benefits are (i) less computation and hence less error and consequently a better quality of solution and (ii) reduced storage requirements. In literature, the pruning concept is not in vogue so far although it is most desirable. It is assumed that at least one information, i.e. one equation is known to be correct and which will be our first equation. In a numerical linear system, the system could be slightly inconsistent or inconsistent of varying degree. If the system is too inconsistent, then we should fall back on to the physical problem (PP), check the correctness of the PP derived from the material universe, modify it, if necessary, and then check the corresponding mathematical model (MM) and correct it. In nature/material universe, inconsistency is completely nonexistent. If the MM becomes inconsistent, it could be due to error introduced by the concerned measuring device and/or due to assumptions made on the PP to obtain an MM which is relatively easily solvable or simply due to human error. No measuring device can usually measure a quantity with an accuracy greater that 0.005% or, equivalently with a relative error less than 0.005%. Hence measurement error is unavoidable in a numerical linear system when the quantities are continuous (or even discrete with extremely large number). Assumptions, though not desirable, are usually made when we find the problem sufficiently difficult to be solved within the available means/tools/resources and hence distort the PP and the corresponding MM. The . error thus introduced in the system could (not always necessarily though) make the system somewhat inconsistent. If the inconsistency (contradiction) is too much then one should definitely not proceed to solve the system in terms of getting a least-squares solution or the minimum-norm least-squares solution. All these solutions will be invariably of no real-world use. If, on the other hand, inconsistency is reasonably low, i.e. the system is near-consistent or, equivalently, has near-linearly-dependent rows, then the foregoing solutions are useful. Pruning in such a near-consistent system should be performed based on the desired accuracy and on the definition of near-linear dependence. In this article, we discuss pruning over various kinds of linear systems and strongly suggest its use as a pre-processor or as a part of an algorithm. Ideally pruning should (i) be a part of the solution process (algorithm) of the system, (ii) reduce both computational error and complexity of the process, and (iii) take into account the numerical zero defined in the context. These are precisely what we achieve through our proposed O(mn2) algorithm presented in Matlab, that uses a subprogram of solving a single linear equation and that has embedded in it the pruning.

Sen, Syamal K.↗

Mini-BRU/BIPS foil bearing development

The analysis revealed the failure agent to be a combination of poor teflon coating adhesion, a decrease in bearing sway space and, possibly, lack of flushing flow through the bearing. A change in Teflon coating vendors provided substantially improved coating quality and surface finish. The sway space was increased and the cooling bleed flow was adjusted to flush the bearing. These changes were included in a test conducted in the WHL from 6 April to 22 May 1978 which resulted in the completion of 1006.9 hours of operation at temperature and load. Post-test inspection revealed the bearings to be in excellent condition and capable of completing a much longer test.

Dobler, F. X.↗

Developing a Logistics Data Process for Support Equipment for NASA Ground Operations

The United States NASA Space Shuttle has long been considered an extremely capable yet relatively expensive rocket. A great part of the roughly US $500 million per launch expense was the support footprint: refurbishment and maintenance of the space shuttle system, together with the long list of resources required to support it, including personnel, tools, facilities, transport and support equipment. NASA determined to make its next rocket system with a smaller logistics footprint, and thereby more cost-effective and quicker turnaround. The logical solution was to adopt a standard Logistics Support Analysis (LSA) process based on GEIA-STD-0007 http://www.logisticsengineers.org/may09pres/GEIASTD0007DEXShortIntro.pdf which is the successor of MIL-STD-1388-2B widely used by U.S., NATO, and other world military services and industries. This approach is unprecedented at NASA: it is the first time a major program of programs, Project Constellation, is factoring logistics and supportability into design at many levels. This paper will focus on one of those levels NASA ground support equipment for the next generation of NASA rockets and on building a Logistics Support Analysis Record (LSAR) for developing and documenting a support solution and inventory of resources for. This LSAR is actually a standards-based database, containing analyses of the time and tools, personnel, facilities and support equipment required to assemble and integrate the stages and umbilicals of a rocket. This paper will cover building this database from scratch: including creating and importing a hierarchical bill of materials (BOM) from legacy data; identifying line-replaceable units (LRUs) of a given piece of equipment; analyzing reliability and maintainability of said LRUs; and therefore making an assessment back to design whether the support solution for a piece of equipment is too much work, i.e., too resource-intensive. If one must replace or inspect an LRU too much, perhaps a modification of the design of the equipment can make such operational effort unnecessary. Finally, this paper addresses processes of tying resources to a timeline of tasks performed in ground operations: this enables various overarching analyses, e.g., a summarization of all resources used for a given piece of equipment. Quality Control of data will also be discussed: importing and exporting data from product teams, including spreadsheets-todatabase or data exchange between databases.

Chakrabarti, Suman↗

Development and Implementation of Nationally Recognized Laboratory for Material Characterization in the Microwave and Millimeter Wave Bands

This report provides a progress update for establishing a laboratory for material characterization in the microwave and millimeter wave bands. During the launch of STS-124 a large area of refractory bricks was liberated from the flame trench built for the exhaust of the solid rocket motors (SRM). The inspection of the liberated area revealed many defects, debonds, corrosion and voids that are a cause for concern relating to the health of the entire flame trench wall. A request for assistance was received for the nondestructive evaluation (NDE) of these anomalies behind the refractory bricks, with the primary interest being a health assessment based on the quality of the brick, epoxy and concrete bond.

Hepburn, Frank L.↗

Various Types of Defects Detection in Flat and Curved Laminated Composite Plates using Nonintrusive Lamb Wave System

Composite materials are widely used in aerospace industries due to their light weight, strength, and various other desired properties. However, they are susceptible to various defects occurring during the manufacturing process or in service. Typical defects include porosity, wrinkles, and delamination. Nondestructive means of detection of the defects at any stage are of great importance to ensure quality and safety of composite structures. A nonintrusive removeable Lamb wave system and accompanied methodology that is not material-dependent is presented in this paper to detect various types of typical defects in laminated composite plates, flat or curved. Through multidimensional data acquisition and processing, abnormality in waves caused by defects is captured and presented in inspection images. The methodologies are demonstrated in 2 cases: flat plate with wrinkles, and curved plate with delamination. Overall the results show that Lamb waves using the piezoelectric transducer and laser vibrometer system can be used for various types of defects inspection in flat or curved composite plates.

composite structures↗

The Boeing 747 fatigue integrity program

The fatigue integrity program which was established to insure economic operations and to provide foundation data for inspection and maintenance is discussed. Significant features of the 747 fatigue integrity program are: (1) fatigue analyses which are continually updated to reflect design changes, fatigue test results, and static and flight load survey measurements; (2) material selection and detail design by using initial fatigue analyses, service experience, and testing; and (3) fatigue testing to check detail design quality and to verify the analyses, culminated by the test of a structurally complete airframe. Fatigue stress analyses were performed with the aid of experimental as well as analytical procedures. Extensive application was made of the stress severity factor, developed at Boeing, for evaluating peak stresses in complex joints. A frame of reference was established by families of structural fatigue performance curves (S-N curves) encompassing the range of materials and fatigue qualities anticipated for the 747 airplane design.

Spencer, M. M.↗

HO(x) Measurements in SONEX with the Airborne Tropospheric Hydrogen Oxides Sensor (ATHOS)

SONEX, which was delayed by aircraft inspection problems, began the second week of October and concluded in mid-November with 16 flights. These flights covered the Pacific Ocean off the western United States, transits across the United States, the western coast of Europe, and the North and Central Atlantic Ocean. Particular attention was paid to the North Atlantic Flight Corridor. ATHOS collected high-quality HO(x) data on 15 flights. Observations taken at 5 Hz were typically averaged into 20-second measurements. Each 20-second measurement has precision 1(sigma) of less than 0.01 pptv. OH measurements were generally made from the surface to flight altitudes. HO2 measurements, which require reagent NO flow, were made from flight altitudes to near the top of the planetary boundary layer. Measured OH and HO2 during SONEX was generally lower than the measured OH and HO2 during SUCCESS (April-May, 1996, central United States). Whereas during SUCCESS midday OH was 0.1-0.5 pptv and HO2 was 3-15 pptv, during SONEX midday OH was 0.02-0.2 pptv and HO2 was 0.5-8 pptv. Part of this difference results from the midday solar zenith angles, which were larger during SONEX than during SUCCESS due to both the season and the generally higher latitudes sampled during SONEX. However, some of the difference may be due to differences in HOx sources, since less air influenced by convection was sampled during SONEX. These possibilities await post-flight calibrations of ATHOS and analysis of observations of HO(x) and simultaneously measured meteorology and trace species.

Brune, William M.↗

Thermographic Qualification of Graphite/Epoxy Instrumentation Racks

A nondestructive evaluation method is desired for ensuring the 'as manufactured' and 'post service' quality of graphite/epoxy instrumentation rack shells. The damage tolerance and geometry of the racks dictate that the evaluation method be capable of identifying defects, as small as 0.25 inch 2 in area, over large acreage regions, tight compound radii and thickness transition zones. The primary defects of interest include voids, inclusions, delaminations and porosity. The potential for an infrared thermographic inspection to replace ultrasonic testing, for qualifying the racks as 'defect free' is under investigation. The inspection process is validated by evaluating defect standard panels built to the same specifications as the racks, except for the insertion of artificial fabricated defects. The artificial defects are designed to match those which are most prevalent in the actual instrumentation racks. A target defect area of 0.0625 inch 2 (a square with 0.25 inch on a side) was chosen for the defect standard panels to ensure the ability to find all defects of the critical (0.25 inch squared) size.

Walker, James L.↗

Multilayer X-ray mirrors - Interfacial roughness, scattering, and image quality

Scattering of the multilayer coatings used for our normal incidence soft X-ray telescope at a wavelength of 63.5 A has been measured at 1.54 A and grazing angles of incidence and at soft X-rays near normal incidence. Furthermore, the edge of the moon is used as a known test target to estimate the amount of scattering in the arcsec range from images obtained on the date of the solar eclipse on July 11, 1991. The internal surfaces of the coating are inspected by high-resolution electron microscopy. A theoretical model describing the evolution and replication of roughness from layer to layer throughout the structure, which is in agreement with all experimental data, is presented. We find that practically all roughness caused by the growth of the multilayer structure occurs at spatial frequencies which are too high to produce scattering. The substrate roughness is replicated at lower spatial frequencies which might produce scattering within the field of view of an instrument. However, roughness in this range is below the 0.5 A level, again resulting in insignificant amounts of scatter.

Spiller, Eberhard↗

Manufacturing Aids

During a research program, MMTC/Textron invented a computer-aided automatic robotic system for spraying hot plasma onto a turbine blade. The need to control the thickness of the plasma deposit led to the development of advanced optical gaging techniques to monitor and control plasma spray build-up on blade surfaces. The techniques led to computerized optical gages for inspecting aircraft, industrial turbine blades, etc. MMTC offers 10 standard commercial robotic gages. The system also generates two dimensional profiles for assessing status and specifying repairs to the electromechanical cathodes used to make the parts. It is capable of accuracies to a ten-thousandth of an inch. An expanded product line is currently marketed. The gages offer multiple improvements in quality control and significant savings.

Source record↗

A Review of LIBS for Real-Time Detection of Trace Silicone Contaminants on CFRP Surfaces

Laser ablation is the removal of material by laser pulses through photochemical, photothermal, or photophysical mechanisms, which is useful to prepare an adherend surface for adhesive bonding. Laser surface treatment is a method that has been under research for the past decade at NASA Langley Research Center (LaRC) to prepare surfaces for adhesive joining of aerospace composite materials and metallic alloys. Laser ablation of composite materials increases surface area and removes the surface contaminants introduced during material handling and fabrication processes. By adjustment of laser parameters, it is possible to obtain repeatable surface conditions, and superficial contaminants can be selectively and efficiently removed without damaging the underlying carbon fibers or the carbon fiber reinforced polymer (CFRP) substrate. Laser induced breakdown spectroscopy (LIBS) is a surface characterization and inspection technique that can be seamlessly integrated into the laser surface treatment process. At NASA LaRC, a single laser system has been used for both laser surface treatment and LIBS, which enables in-situ monitoring of surface contaminants. This work focuses on the advancements at LaRC using LIBS to detect surface silicone contaminants on aerospace CFRP materials and to provide surface quality control in adhesive bonding.

Rodolfo I Ledesma↗