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At least 343 records · Page 19

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials Using MALAMUTE

Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy, aims to develop and qualify additively-manufactured materials for nuclear applications. The key challenges to these efforts are the microstructural variabilities observed on the AM products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-through-put experimental and modeling techniques to accelerate the qualification efforts. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the AM process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture the microstructural variabilities is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning modeling capabilities to develop a digital twin for AM that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation for AM materials. The melting and subsequent solidification that occurs during the AM process is a complex phenomenon that requires multiscale multiphysics analysis. Idaho National Laboratory’s (INL) Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for AM materials in an efficient, reliable, and cost-effective way. This work package focuses on understanding the role of process variabilities on the various microstructural characteristics of the AM materials. Microstructures unique to AM materials, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. In fiscal year (FY) 24, we significantly advanced upon our work in the last fiscal year, both on physics-based and ML models. The alloy solidification model available in MOOSE has been extended to incorporate the thermodynamic properties and free energy relevant to 316SS. The model demonstrates the Cr segregation that occurs during solidifcation. It is demonstrated that rate of solidification and solute segregation is primarily influence by the cooling rate dictating the level of freezing. This work captures the microstructural variabilities at the subgrain level that are often missing in the part-scale models. With an aim to connect the microstructural evolution model to realistic process conditions, a reduced order model is developed for predicting the thermal conditions around meltpool from high-fidelity process simulations. Furthermore, machine learning approach is used to accelerate the temperature prediction during the AM process. In the following years, MALAMUTE will be used to connect different aspects of the models and quantitatively predict the microstructural evolution. The developed ML-based surrogate model will consider the process conditions as the input to predict the microstructural features in a cost-effective way. The generated microstructures can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work help identify the key microstructural features at the subgrain level that are significant in property/performance prediction of the AM products. This work will provide inputs to the large-scale process variability models to reevaluate and validate assumptions/simplifications made in the part-scale models. Furthermore, through active learning this work will help identify the data need from both modeling and experimental sides for development of a robust digital twin for AM.

36 MATERIALS SCIENCE↗

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials using MALAMUTE

The Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy aims to develop and qualify additively manufactured materials for nuclear applications. One key challenge to this is the microstructural variability observed in the additively manufactured products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-throughput experimental and modeling techniques to accelerate qualification. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the additive manufacturing process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture microstructural variability is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning models to develop a digital twin for additive manufacturing that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation. The melting and subsequent solidification that occurs during the additive process is a complex phenomenon that requires multiscale multiphysics analysis. This work package focuses on understanding the role of process variabilities on the unique microstructural characteristics of additively manufactured materials. Microstructural features at the subgrain level, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. Idaho National Laboratory’s Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for additively manufactured materials in an efficient, reliable, and cost-effective way. This work focuses on capturing the microstructural variabilities at the subgrain level that are often missing in the part-scale models. In fiscal year 2025, we significantly advanced upon our work in the last fiscal year, in terms of the predictive capabilities of the physics-based and ML models, by adding the capabilities to capture subgrain-level micro-segregation during solidification using phase-field model and to predict the time-dependent dynamics of the AM process through the MOGPAR model. The alloy solidification model in MOOSE incorporates the thermodynamic properties and free energy relevant to 316 stainless steel. The model demonstrates the Cr and Ni segregation that occurs during solidification, including that the rate of solidification. The microstructural evolution model is connected to the process conditions via the surrogate model developed in this work. This enables predictions of the final microstructure in conjunctions with the manufacturing process. This work supports AMMT's rapid qualification goals by laying the foundation for an efficient and cost-effective model establishing the PSPP correlation for AM. The generated microstructures and predicted micro-segregation can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work helps to identify the key microstructural features at the subgrain level that are significant in property and performance predictions of additively manufactured components. This work will also provide inputs to the large-scale process variability models to reevaluate and validate assumptions and simplifications made in the part-scale models. Furthermore, through active learning this work can help identify the data need from both modeling and experimental sides for development of a robust digital twin for additive manufacturing and accelerate the AMMT's qualification efforts.

36 - MATERIALS SCIENCE↗

Feasibility of determining flat roof heat losses using aerial thermography

The utility of aerial thermography for determining rooftop heat losses is investigated. Actual rooftop heat losses were obtained both from in-situ instrumentation of test roofs with known thermal resistances and aerial thermography obtained from overflights at an altitude of 305 m. It is found that the roof heat losses calculated using the remotely determined roof temperature agreed to within 17% of those calculated from ground measurements. However it is noted that an acceptable quantitative determination of roof heat losses using aerial thermography is only feasible when the convective term is accurately known or minimized. In addition, the sensitivity of the heat loss determination to environmental conditions is also evaluated. Finally, the analysis shows that the most reliable determinations can probably be obtained under conditions of total cloud cover with low wind speeds and at low ambient temperatures.

Bowman, R. L.↗

A model for the use of satellite remote sensing for the measurement of primary production in the ocean

A model of primary production based upon the responses of phytoplankton to differing light and nutrient fields is described. This model includes the effects on production of variations in surface pigment concentration, the mixed layer depth, and the dependence on the incident solar irradiance. The model has been tested using in situ data provided by the Southern California Bight Studies of Eppley, et al. (1979), the California Cooperative Fisheries Investigations, the Organization of Persistent Upwelling Structures, and other data sets. A synoptic measure of the distribution of surface pigments is derived from the West Coast Chlorophyll and Temperature Time Series. The features and behavior of the model are presented together with the results of the model verification.

Collins, Donald J.↗

BOREAS HYD-1 Soil Hydraulic Properties

The Boreal Ecosystem-Atmosphere Study (BOREAS) Hydrology (HYD)-1 team coordinated a program of data collection to measure and monitor soil properties in collaboration with other science team measurement needs. This data set contains soil hydraulic properties determined at the Northern Study Area (NSA) and Southern Study Area (SSA) flux tower sites based on analysis of in situ tension infiltrometer tests and laboratory-determined water retention from soil cores collected during the 1994-95 field campaigns. Results from this analysis are saturated hydraulic conductivity, and fitting parameters for the van Genuchten-Mualem soil hydraulic conductivity and water retention function at flux tower sites. The data are contained in tabular ASCII files. The HYD-01 soil hydraulic properties data are available from the Earth Observing System Data and Information System (EOSDIS) Oak Ridge National Laboratory (ORNL) Distributed Active Archive Center (DAAC). The data files are available on a CD-ROM (see document number 20010000884).

Hall, Forrest G.↗

Experimental Partitioning of Cr(3+) and Sc(3+) into Olivine: Mechanisms and Implications

Olivine (Mg, Fe)Si2O4 does not, by stoichiometry, accept cations such as Sc(3+) or Cr(3+). However, the partition coefficients of Sc and Cr between olivine and liquid are significant 0.2-1.0. We have measured Cr(3+) partition coefficients of near unity and have grown olivines with nearly 3 wt.% Sc2O3. Therefore, there must be a simple means of charge balancing 3+ ions in a crystal structure that was obviously not designed to receive other than 2+ ions on the olivine M sites. The simplest explanation is that two 3+ ions enter the olivine structure by displacing three 2+ ions and creating an M site vacancy. Even this explanation has difficulties. For minor elements in our experiments (~1 wt.%) the odds of a minor element 3+ ion finding a second 3+ for charge balance are of the order of 100:1 against. Because of the reducing conditions of our experiments, Fe(3+) will not suffice; and Al(3+) is not in sufficient quantity in olivine for charge balance. Therefore, Cr or Sc must, in effect, charge balance itself. For true trace elements, the problem is compounded many times. For an ion at the 10 ppm level the chances of finding a second (for example) Sc ion is approx.10(exp 5):1 against. Of course, any other 3+ ion would suffice but comparisons between percent level doping experiments and trace level partitioning indicate that Henry s law is obeyed. This implies that the same substitution mechanism occurs at both the percent and tens of ppm levels. There are two simple solutions to this problem: (i) The electrical conductivity of olivine is such that charge balance need not be local. This requires substantial domains within the olivine crystal in electrical contact by migration of vacancies or electronic defects. (ii) The 3+ cation brings along its own charge-balancing ion because it existed as a dimer in the silicate liquid. Olivine is not a true insulator but is actually a p-type semiconductor. Even so, electrical communication by this means is unlikely over the tens or hundreds of unit cells that would be required for charge balance to be local. Therefore, we cautiously favor the idea that melt speciation is the means by which 3+ ions enter the olivine structure. Possibly this model might be tested by in situ XAFS measurements or by molecular dynamical calculations.

Jones, John↗

Vibration Performance Comparison Study on Current Fiber Optic Connector Technologies

Fiber optic cables are increasingly being used in harsh environments where they are subjected to vibration. Understanding the degradation in performance under these conditions is essential for integration of the fibers into the given application. System constraints oftentimes require fiber optic connectors so subsystems can be removed or assembled as needed. In the present work, various types of fiber optic connectors were monitored in-situ during vibration testing to examine the transient change in optical transmission and the steady-state variation following the event. Inspection of the fiber endfaces and connectors was performed at chosen intervals throughout the testing.

Ott, Melanie N.↗

Solar Concentrator Demonstrator for Lunar Regolith Processing

NASA at the Marshall Space Flight Center (MSFC) is building a portable inflatable solar concentrator ground demonstrator for use in testing in-situ resource utilization (ISRU) lunar regolith processing methods. Of primary interest is the production of oxygen as a propellant oxidizer and for life support. There are various processes being proposed for the in-situ reduction of the lunar regolith, the leading processes are hydrogen reduction, carbothermal reduction and vapor phase pyrolysis. The concentrator system being built at MSFC could support demonstrations of all of these processes. The system consists of a light inflatable concentrator that will capture sunlight and focus it onto a receiver inside a vacuum chamber. Inflatable concentrators are good for space based applications due to their low weight and dense packaging at launch. The hexapod design allows the spot size to be increased to reduce the power density if needed for the process being demonstrated. In addition to the hardware development, a comprehensive simulation model is being developed and will be verified and validated using the system hardware. The model will allow for the evaluation of different lunar locations and operational scenarios for the lunar regolith processing with a high confidence in the predicted results.

Fikes, John C.↗

NASA Tech Briefs, November 2012

The topics include: Visual System for Browsing, Analysis, and Retrieval of Data (ViSBARD); Time-Domain Terahertz Computed Axial Tomography NDE System; Adaptive Sampling of Time Series During Remote Exploration; A Tracking Sun Photometer Without Moving Parts; Surface Temperature Data Analysis; Modular, Autonomous Command and Data Handling Software with Built-In Simulation and Test; In-Situ Wire Damage Detection System; Amplifier Module for 260-GHz Band Using Quartz Waveguide Transitions; Wideband Agile Digital Microwave Radiometer; Buckyball Nucleation of HiPco Tubes; FACT, Mega-ROSA, SOLAROSA; An Integrated, Layered-Spinel Composite Cathode for Energy Storage Applications; Engineered Multifunctional Surfaces for Fluid Handling; Polyolefin-Based Aerogels; Adjusting Permittivity by Blending Varying Ratios of SWNTs; Gravity-Assist Mechanical Simulator for Outreach; Concept for Hydrogen-Impregnated Nanofiber/Photovoltaic Cargo Stowage System; DROP: Durable Reconnaissance and Observation Platform; Developing Physiologic Models for Emergency Medical Procedures Under Microgravity; Spectroscopic Chemical Analysis Methods and Apparatus; Low Average Sidelobe Slot Array Antennas for Radiometer Applications; Motion-Corrected 3D Sonic Anemometer for Tethersondes and Other Moving Platforms; Water Treatment Systems for Long Spaceflights; Microchip Non-Aqueous Capillary Electrophoresis (MicronNACE) Method to Analyze Long-Chain Primary Amines; Low-Cost Phased Array Antenna for Sounding Rockets, Missiles, and Expendable Launch Vehicles; Mars Science Laboratory Engineering Cameras; Seismic Imager Space Telescope; Estimating Sea Surface Salinity and Wind Using Combined Passive and Active L-Band Microwave Observations; A Posteriori Study of a DNS Database Describing Super critical Binary-Species Mixing; Scalable SCPPM Decoder; QuakeSim 2.0; HURON (HUman and Robotic Optimization Network) Multi-Agent Temporal Activity Planner/Scheduler; MPST Software: MoonKommand

Source record↗

Combining Through-Thickness Reinforcement and Self-Healing for Improved Damage Tolerance and Durability of Composites

A study was undertaken to develop a prototype method for adding through-thickness hollow glass tubes infused with uncured resin and hardener in a carbon Z-pin through-thickness reinforcement field embedded in a composite laminate. Two types of tube insertion techniques were attempted in an effort to ensure the glass tubes survived the panel manufacturing process. A self-healing resin was chosen with a very low viscosity, two component, liquid epoxy resin system designed to be mixed at a 2-to-1 ratio of epoxy to hardener. IM7/8552 carbon epoxy double cantilever beam (DCB) specimens were cut from the hybrid Z-pin and glass tube reinforced panels and tested. In-situ injection of resin and hardener directly into glass tubes, in a staggered pattern to allow for 2-to-1 ratio mixing, resulted in partial healing of the fracture plane, but only if the injection was performed while the specimen was held at maximum load after initial fracture. Hence, there is some potential for healing delamination via resin and hardener delivered through a network of through-thickness glass tubes, but only if the tubes are connected to a reservoir where additional material may be injected as needed.

O'Brien, T. Kevin↗

Design and Fabrication of a Temperature-Controlled Fueled Molten Salt Capsule Irradiation Experiment

Idaho National Laboratory (INL) is developing a Molten salt Research Temperature-controlled Irradiation (MRTI) experimental capsule for the Neutron Radiography (NRAD) reactor. The experiment is envisaged to be versatile and able to host a variety of salt-wall material combinations. The first test is designed to contain actinide-bearing chloride salt, which previously has not been subjected to a neutron field. The main objectives of the experiment are to produce irradiated salt samples for Post Irradiation Examination (PIE), to evaluate salt behavior under irradiation, and to test in-situ sensors/instrumentation. The final design for the experiment completed in 2022, and fabrication of the experiment is underway. The salt is double encapsulated providing insulation and redundancy in the case of leakage. A gas-gap between the inner capsule and the outer container enables tuning of thermal conduction to the NRAD coolant by altering its thickness and its gas-mixture. An inert gas mixture ratio in the gas-gap ensures the configurations reached a targeted average salt temperature of 600oC, while avoiding salt freezing or exceeding material limits. A resistive heater placed within a thermowell and controls the temperature of the experiment (both when the reactor is on or off). The selected configurations can contain over 10 cm3 of fuel-bearing chloride salt, which is sufficient for the purposes of the post-irradiation examination (PIE) and provides sufficient volume for two submerged thermocouple probes to monitor salt temperature. The capsule wall material is Inconel 625, and weld qualifications for the assembly have been developed. A glove-box laser weld technique was refined as part of this process to ensure a leak-tight assembly for the salt-bearing assembly and reduce the risks of impurities permeating into the salt. This work was supported through the INL Laboratory Directed Research & Development (LDRD) Program under DOE Idaho Operations Office Contract DE-AC07-05ID14517.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

ENYGF 2023 - Design of Temperature-controlled Fuel-salt Irradiation Experiment

Idaho National Laboratory (INL) is developing a Molten salt Research Temperature-controlled Irradiation (MRTI) experimental capsule for the Neutron Radiography (NRAD) reactor. The experiment is envisaged to be versatile and able to host a variety of salt-wall material combinations. The first test is designed to contain actinide-bearing chloride salt, which previously has not been subjected to a neutron field. The main objectives of the experiment are to produce irradiated salt samples for Post Irradiation Examination (PIE), to evaluate salt behavior under irradiation, and to test in-situ sensors/instrumentation. The final design for the experiment completed in 2022, and fabrication of the experiment is underway. The salt is double encapsulated providing insulation and redundancy in the case of leakage. A gas-gap between the inner capsule and the outer container enables tuning of thermal conduction to the NRAD coolant by altering its thickness and its gas-mixture. An inert gas mixture ratio in the gas-gap ensures the configurations reached a targeted average salt temperature of 600oC, while avoiding salt freezing or exceeding material limits. A resistive heater placed within a thermowell and controls the temperature of the experiment (both when the reactor is on or off). The selected configurations can contain over 10 cm3 of fuel-bearing chloride salt, which is sufficient for the purposes of the post-irradiation examination (PIE) and provides sufficient volume for two submerged thermocouple probes to monitor salt temperature. The capsule wall material is Inconel 625, and weld qualifications for the assembly have been developed. A glove-box laser weld technique was refined as part of this process to ensure a leak-tight assembly for the salt-bearing assembly and reduce the risks of impurities permeating into the salt. This work was supported through the INL Laboratory Directed Research & Development (LDRD) Program under DOE Idaho Operations Office Contract DE-AC07-05ID14517.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Final Report on Characterization of Irradiated Sensors and Coupling Adhesive Bonds

This report summarizes characterization via scanning/transmission electron microscopy of the microstructures of the unirradiated and irradiated piezoelectric ultrasonic sensor/aluminum substrate assemblies using four commercially available inorganic coupling adhesives to bond two types of piezoelectric crystals to the substrates. The sample assemblies were irradiated in the PULSTAR reactor at NC State University and ultrasonic data was collected in-situ. ORNL LAMDA Laboratory capabilities were utilized to perform pre- and post-irradiation examination of the sensor assemblies. This document summarizes the PIE performed at the ORNL LAMDA laboratory. The results of the PIE described in this report are consistent with the ultrasonic data collected during irradiation – in particular, high temperature epoxy adhesive seemed to provide the best coupling as compared to the refractory ceramic adhesives. It was determined that the quality of the sensor-adhesive-substrates governed the ultrasonic performance of the sensors. It was also apparent that irradiation did not significantly affect bond quality, which is also supported by the ultrasonic data collected during irradiation. A more comprehensive DOE NSUF Final Report including details of materials selection, sample fabrication, initial ultrasonic testing, irradiation and in-situ ultrasonic testing, positron annihilation lifetime spectroscopy and doppler broadening spectroscopy performed at EPRI and NC State University will be published at the conclusion of the project.

36 MATERIALS SCIENCE↗

In Situ Study on Fracture Behavior of Thick-Section Friction Stir-Welded AA 5083 Alloy

Friction stir welding (FSW) produces a gradient microstructure with distinct metallurgical zones. Here, the present study focuses on characterizing the fracture behavior during uniaxial loading across thick-section FSW joint in nonheat-treatable 5083 aluminum alloy. The hardness variation is linked to microstructural features across the weld zones through correlative microscopy. Notably, the heat-affected zone (HAZ) exhibits a lower hardness of 75 HV, while the thermomechanically affected zone (TMAZ) and stir zones (SZ) display a hardness of around 79HV. A marginal difference in hardness in HAZ prompts strain localization in HAZ on the advancing side of the weld, resulting in offset in fracture from the SZ, which is captured through in situ monitoring of the tensile test. Further, the postdeformation analysis reveals crack propagation along the maximum shear stress plane due to the coalescence of microvoids resulting from the fracturing and debonding of second-phase particles. Overall, this study provides valuable insight for optimizing the FSW process of AA 5083 alloy for thick-section applications.

36 MATERIALS SCIENCE↗

Infrared Astronomical Satellite (IRAS) superfluid helium tank temperature control

The infrared detectors on the Infrared Astronomical Satellite (IRAS), which was placed into a polar orbit in January 1983, are cooled to a temperature of less than 3 K by thermal coupling to the main cryogenic tank (MCT) containing superfluid helium. A porous plug built into the vent line entrance acts as a superfluid helium liquid/vapor separator in zero gravity. A description of the IRAS MCT flight porous plug is presented, and tests of the plug in situ are discussed, taking into account submerged plug tests, a restart test, and a cold vapor flow test. Aspects of flow rate determination in the case of an unavailability of flight flow rate data are also considered.

Petrac, D.↗

Non-invasive Optical End-to-End Test of a Large TMA Telescope (JWST) from the Intermediate Focus

The James Webb Space Telescope (JWST) requires testing of the full optical system in a cryogenic vacuum environment before launch. Challenges with the telescope architecture and the test environment lead to placing removable optical test sources at the Cassegrain intermediate focus of the Telescope. The Science Instrument suite will be used to align the telescope and to verify the wavefront error. The Science Instruments capture test images that are analyzed using focus diverse phase retrieval. The wavefront sensing algorithms have the large dynamic range required to measure the relatively small wavefronts of interest in the presence of the large aberrations resulting from the off-axis source locations at the intermediate focus. These inherent aberrations of the off-axis design are removed analytically from the measured data. The test design and in-situ wavefront sensing process enables a number of tests to verify the alignment and optical quality of the system.

Whitman, Tony↗

Assessing the Long-Term Stability of Anion Exchange Membranes for Electrochemical CO 2 Reduction

Materials and cell components used in CO 2 electrolysis have largely been adapted from technologies initially developed for water electrolysis and fuel cells. However, electrochemical CO 2 reduction introduces distinct material challenges due to the unique chemical environment in this process. Here, in this study, we conducted ex-situ 1000 h stability tests on commonly used anion exchange membranes, exposing them exclusively to electrolytes and organic molecules used or produced during CO 2 electrolysis, at concentrations relevant to and compatible with postseparation processes. Notably, 15% w/w n-propanol and 5 M acetic acid caused complete dissolution or partial disintegration of the membranes unless cross-linking was present and remained stable throughout the test. When the membranes stayed physically intact, most of them exhibited excellent chemical stability in alkaline medium containing alcohols or formic acid, which was confirmed by vibrational spectroscopy and ion exchange capacity measurements. However, exposure to alcohol-and acid-containing solutions led to a substantial increase in swelling and water uptake, with potential implications for mechanical stability, ion/product crossover, and compression management of adjacent components. The potential effects of CO 2 electroreduction products on membrane stability, their subsequent impact on electrolyzer performance, and mitigation strategies are discussed.

CO2RR↗

Application of Laser Based Ultrasound for NDE of Damage in Thick Stitched Composites

As design engineers implement new composite systems such as thick, load bearing composite structures, they must have certifiable confidence in structure s durability and worthiness. This confidence builds from understanding the structural response and failure characteristics of simple components loaded in testing machines to tests on full scale sections. Nondestructive evaluation is an important element which can provide quantitative information on the damage initiation, propagation, and final failure modes for the composite structural components. Although ultrasound is generally accepted as a test method, the use of conventional ultrasound for in-situ monitoring of damage during tests of large structures is not practical. The use of lasers to both generate and detect ultrasound extends the application of ultrasound to in- situ sensing of damage in a deformed structure remotely and in a non-contact manner. The goal of the present research is to utilize this technology to monitor damage progression during testing. The present paper describes the application of laser based ultrasound to quantify damage in thick stitched composite structural elements to demonstrate the method. This method involves using a Q-switched laser to generate a rapid, local linear thermal strain on the surface of the structure. This local strain causes the generation of ultrasonic waves into the material. A second laser used with a Fabry-Perot interferometer detects the surface deflections. The use of fiber optics provides for eye safety and a convenient method of delivering the laser over long distances to the specimens. The material for these structural elements is composed of several stacks of composite material assembled together by stitching through the laminate thickness that ranging from 0.5 to 0.8 inches. The specimens used for these nondestructive evaluation studies had either impact damage or skin/stiffener interlaminar failure. Although little or no visible surface damage existed, internal damage was detected by laser based ultrasound.

Anastasi, Robert F.↗