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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Predicting strength distributions of MEMS structures using flaw size and spatial density

The populations of flaws in individual layers of microelectromechanical systems (MEMS) structures are determined and verified using a combination of specialized specimen geometry, recent probabilistic analysis, and topographic mapping. Strength distributions of notched and tensile bar specimens are analyzed assuming a single flaw population set by fabrication and common to both specimen geometries. Both the average spatial density of flaws and the flaw size distribution are determined and used to generate quantitative visualizations of specimens. Scanning probe-based topographic measurements are used to verify the flaw spacings determined from strength tests and support the idea that grain boundary grooves on sidewalls control MEMS failure. The findings here suggest that strength controlling features in MEMS devices increase in separation, i.e., become less spatially dense, and decrease in size, i.e., become less potent flaws, as processing proceeds up through the layer stack. The method demonstrated for flaw population determination is directly applicable to strength prediction for MEMS reliability and design.

Instruments & Instrumentation↗
NASA NTRS1985

Fracture of thick graphite/epoxy laminates with part-through surface flaws

Fracture behavior of tensile specimens containing through-the-thickness flaws and part-through semi-elliptic surface flaws was investigated. The material was T300/5208 graphite/epoxy, with a stacking sequence 0/+ or - 45/90 sub ns. Laminate thicknesses ranged from 8 to 120 plies. Fracture toughness for specimens with through-the-thickness flaws was a function of laminate thickness. Fracture toughness was also independent of crack size. Fracture toughness for the thick laminates was also independent of specimen geometry (center-cracked tension specimen, compact tension specimen, and three-point bend specimen). Using the asymptotic value of facture toughness and linear elastic isotropic fracture mechanics, the notched strength of tensile specimens with semi-elliptic surface flaws was predicted. The strength ratio is a function of the flaw depth (a/t) and flaw aspect (a/c) ratios. Comparisons between predicted and experimental strengths are good for large values of a/t. The notched strength of filament wound graphite/epoxy tensile specimens with part-through surface flaws was also predicted.

Morris, D. H.↗
NASA NTRS1986

Fracture of thick graphite/epoxy laminates with part-through surface flaws

Fracture behavior of tensile specimens containing through-the-thickness flaws and part-through semi-elliptic surface flaws was investigated. The material was T300/5208 graphite/epoxy, with a stacking sequence 0/+ or - 45/90 sub ns. Laminate thicknesses ranged from 8 to 120 plies. Fracture toughness for specimens with through-the-thickness flaws was a function of laminate thickness. Fracture toughness was also independent of crack size. Fracture toughness for the thick laminates was also independent of specimen geometry (center-cracked tension specimen, compact tension specimen, and three-point bend specimen). Using the asymptotic value of fracture toughness and linear elastic isotropic fracture mechanics, the notched strength of tensile specimens with semi-elliptic surface flaws was predicted. The strength ratio is a function of the flaw depth (a/t) and flaw aspect (a/c) ratios. Comparisons between predicted and experimental strengths are good for large values of a/t. The notched strength of filament wound graphite/epoxy tensile specimens with part-through surface flaws was also predicted.

Harris, C. E.↗
NASA NTRS2005

Detection and Characterization of Flaws in Sprayed on Foam Insulation with Pulsed Terahertz Frequency Electromagnetic Waves

The detection and repair of flaws such as voids and delaminations in the sprayed on foam insulation of the external tank reduces the probability of foam debris during shuttle ascent. The low density of sprayed on foam insulation along with it other physical properties makes detection of flaws difficult with conventional techniques. An emerging technology that has application for quantitative evaluation of flaws in the foam is pulsed electromagnetic waves at terahertz frequencies. The short wavelengths of these terahertz pulses make them ideal for imaging flaws in the foam. This paper examines the application of terahertz pulses for flaw detection in foam characteristic of the foam insulation of the external tank. Of particular interest is the detection of voids and delaminations, encapsulated in the foam or at the interface between the foam and a metal backing. The technique is shown to be capable of imaging small voids and delaminations through as much as 20 cm of foam. Methods for reducing the temporal responses of the terahertz pulses to improve flaw detection and yield quantitative characterizations of the size and location of the flaws are discussed.

Winfree, William P.↗
NASA NTRS2007

Applicability of a Conservative Margin Approach for Assessing NDE Flaw Detectability

Nondestructive Evaluation (NDE) procedures are required to detect flaws in structures with a high percentage detectability and high confidence. Conventional Probability of Detection (POD) methods are statistical in nature and require detection data from a relatively large number of flaw specimens. In many circumstances, due to the high cost and long lead time, it is impractical to build the large set of flaw specimens that is required by the conventional POD methodology. Therefore, in such situations it is desirable to have a flaw detectability estimation approach that allows for a reduced number of flaw specimens but provides a high degree of confidence in establishing the flaw detectability size. This paper presents an alternative approach called the conservative margin approach (CMA). To investigate the applicability of the CMA approach, flaw detectability sizes determined by the CMA and POD approaches have been compared on actual datasets. The results of these comparisons are presented and the applicability of the CMA approach is discussed.

Koshti, ajay M.↗
NASA NTRS2009

Probabilistic Estimation of Critical Flaw Sizes in the Primary Structure Welds of the Ares I-X Launch Vehicle

The primary structure of the Ares I-X Upper Stage Simulator (USS) launch vehicle is constructed of welded mild steel plates. There is some concern over the possibility of structural failure due to welding flaws. It was considered critical to quantify the impact of uncertainties in residual stress, material porosity, applied loads, and material and crack growth properties on the reliability of the welds during its pre-flight and flight. A criterion--an existing maximum size crack at the weld toe must be smaller than the maximum allowable flaw size--was established to estimate the reliability of the welds. A spectrum of maximum allowable flaw sizes was developed for different possible combinations of all of the above listed variables by performing probabilistic crack growth analyses using the ANSYS finite element analysis code in conjunction with the NASGRO crack growth code. Two alternative methods were used to account for residual stresses: (1) The mean residual stress was assumed to be 41 ksi and a limit was set on the net section flow stress during crack propagation. The critical flaw size was determined by parametrically increasing the initial flaw size and detecting if this limit was exceeded during four complete flight cycles, and (2) The mean residual stress was assumed to be 49.6 ksi (the parent material s yield strength) and the net section flow stress limit was ignored. The critical flaw size was determined by parametrically increasing the initial flaw size and detecting if catastrophic crack growth occurred during four complete flight cycles. Both surface-crack models and through-crack models were utilized to characterize cracks in the weld toe.

Pai, Shantaram S.↗
NASA NTRS2014

Determination of Flaw Size from Thermographic Data

Conventional methods for reducing the pulsed thermographic responses of delaminations tend to overestimate the size of the flaw. Since the heat diffuses in the plane parallel to the surface, the resulting temperature profile over the flaw is larger than the flaw. A variational method is presented for reducing the thermographic data to produce an estimated size for the flaw that is much closer to the true size of the flaw. The size is determined from the spatial thermal response of the exterior surface above the flaw and a constraint on the length of the contour surrounding the flaw. The technique is applied to experimental data acquired on a flat bottom hole composite specimen.

Winfree, William P.↗
DOE OSTI2015

Identify Structural Flaw Location and Type with an Inverse Algorithm of Resonance Inspection

To evaluate the fitness-for-service of a structural component and to quantify its remaining useful life, aging and service-induced structural flaws must be quantitatively determined in service or during scheduled maintenance shutdowns. Resonance inspection (RI), a non-destructive evaluation (NDE) technique, distinguishes the anomalous parts from the good parts based on changes in the natural frequency spectra. Known for its numerous advantages, i.e., low inspection cost, high testing speed, and broad applicability to complex structures, RI has been widely used in the automobile industry for quality inspection. However, compared to other contemporary direct visualization-based NDE methods, a more widespread application of RI faces a fundamental challenge because such technology is unable to quantify the flaw details, e.g. location, dimensions, and types. In this study, the applicability of a maximum correlation-based inverse RI algorithm developed by the authors is further studied for various flaw cases. It is demonstrated that a variety of common structural flaws, i.e. stiffness degradation, voids, and cracks, can be accurately retrieved by this algorithm even when multiple different types of flaws coexist. The quantitative relations between the damage identification results and the flaw characteristics are also developed to assist the evaluation of the actual state of health of the engineering structures.

non-destructive evaluation, resonance inspection, ↗
NASA NTRS1974

Deep flaws in weldments of aluminum and titanium

Surface flawed specimens of 2219-T87 and 6Al-4V STA titanium weldments were tested to determine static failure modes, failure strength, and fatigue flaw growth characteristics. Thicknesses selected for this study were purposely set at values where, for most test conditions, abrupt instability of the flaw at fracture would not be expected. Static tests for the aluminum weldments were performed at room, LN2 and LH2 temperatures. Titanium static tests for tests were performed at room and LH2 temperatures. Results of the static tests were used to plot curves relating initial flaw size to leakage- or failure-stresses (i.e. "failure" locus curves). Cyclic tests, for both materials, were then performed at room temperature, using initial flaws only slightly below the previously established failure locus for typical proof stress levels. Cyclic testing was performed on pairs of specimens, one with and one without a simulated proof test cycle. Comparisons were made then to determine the value and effect of proof testing as affected by the various variables of proof and operating stress, flaw shape, material thickness, and alloy.

Masters, J. N.↗
NASA NTRS1981

Digital ultrasonics signal processing: Flaw data post processing use and description

A modular system composed of two sets of tasks which interprets the flaw data and allows compensation of the data due to transducer characteristics is described. The hardware configuration consists of two main units. A DEC LSI-11 processor running under the RT-11 sngle job, version 2C-02 operating system, controls the scanner hardware and the ultrasonic unit. A DEC PDP-11/45 processor also running under the RT-11, version 2C-02, operating system, stores, processes and displays the flaw data. The software developed the Ultrasonics Evaluation System, is divided into two catagories; transducer characterization and flaw classification. Each category is divided further into two functional tasks: a data acquisition and a postprocessor ask. The flaw characterization collects data, compresses its, and writes it to a disk file. The data is then processed by the flaw classification postprocessing task. The use and operation of a flaw data postprocessor is described.

Buel, V. E.↗
NASA NTRS1983

Growth and stability of interacting surface flaws of arbitrary shape

Growth regimes of interacting surface flaws of arbitrary shape are analyzed with the aid of the body force method, and the stability of the process is assessed on the basis of the variation of the load during the growth. It is shown that irregularly shaped flaws are often associated with very high stress intensity factors locally, which tend to change as the flaws grow into more regular shapes. Several examples of various flaw shapes are worked out for illustration, and it is shown that a simple formula seems to provide an accurate estimate of the maximum stress intensity factor for surface flaws of various shapes, which are not very slender. The formula involves the overall maximum tension, as well as the area of the projection of the flaw on the plane normal to the maximum tension.

Murakami, Y.↗
NASA NTRS2008

Elastic-Plastic Fracture Mechanics Analysis of Critical Flaw Size in ARES I-X Flange-to-Skin Welds

NASA's Ares 1 Upper Stage Simulator (USS) is being fabricated from welded A516 steel. In order to insure the structural integrity of these welds it is of interest to calculate the critical initial flaw size (CIFS) to establish rational inspection requirements. The CIFS is in turn dependent on the critical final flaw size (CFS), as well as fatigue flaw growth resulting from transportation, handling and service-induced loading. These calculations were made using linear elastic fracture mechanics (LEFM), which are thought to be conservative because they are based on a lower bound, so called elastic, fracture toughness determined from tests that displayed significant plasticity. Nevertheless, there was still concern that the yield magnitude stresses generated in the flange-to-skin weld by the combination of axial stresses due to axial forces, fit-up stresses, and weld residual stresses, could give rise to significant flaw-tip plasticity, which might render the LEFM results to be non-conservative. The objective of the present study was to employ Elastic Plastic Fracture Mechanics (EPFM) to determine CFS values, and then compare these values to CFS values evaluated using LEFM. CFS values were calculated for twelve cases involving surface and embedded flaws, EPFM analyses with and without plastic shakedown of the stresses, LEFM analyses, and various welding residual stress distributions. For the cases examined, the computed CFS values based on elastic analyses were the smallest in all instances where the failures were predicted to be controlled by the fracture toughness. However, in certain cases, the CFS values predicted by the elastic-plastic analyses were smaller than those predicted by the elastic analyses; in these cases the failure criteria were determined by a breakdown in stress intensity factor validity limits for deep flaws (a greater than 0.90t), rather than by the fracture toughness. Plastic relaxation of stresses accompanying shakedown always increases the calculated CFS values compared to the CFS values determined without shakedown. Thus, it is conservative to ignore shakedown effects.

Chell, G. Graham↗
DOE OSTI2018

APPLICATION OF THE FAVOR-OCI FRACTURE MECHANICS COMPUTER PROGRAM TO ASME CODE SECTION XI, IWB-3610 FLAW ACCEPTANCE CRITERIA EVALUATIONS

This paper presents an overview of added features in a new version of the FAVOR (Fracture Analysis of Vessels Oak Ridge) computer code called FAVOR-OCI. The original FAVOR code was developed at the US Department of Energy’s Oak Ridge National Laboratory (ORNL) under the sponsorship of the US Nuclear Regulatory Commission (NRC). FAVOR is applied by US and international nuclear power industries to perform deterministic and probabilistic fracture mechanics analyses of commercial nuclear reactor pressure vessels (RPVs). Appli-cations of FAVOR are focused on insuring that the structural integrity of aging, and increasingly embrittled, RPVs is main-tained throughout their licensed service life. Based on the final ORNL release of FAVOR, v16.1, FAVOR-OCI extends existing deterministic features of FAVOR while preserving all prev-iously-existing probabilistic capabilities of FAVOR.The objective of this paper is to describe new deterministic features in FAVOR-OCI that can be applied to analytical evaluations of planar flaws. These evaluations are consistent with the acceptance criteria of ASME Code, Section XI, Article IWB-3610, including Subarticles IWB-3611 (acceptance based on flaw size) and IWB-3612 (acceptance based on applied stress intensity factor). The linear elastic fracture mechanics (LEFM) capabilities of FAVOR-OCI also incorporate the analytical procedures presented in the Nonmandatory Appendix A, Analysis of Flaws, Article A-3000, Method of KI Determination, for both surface and subsurface (embedded) flaws.The paper describes a computational methodology for determining critical values of fracture-related parameters that satisfy ASME Code Section XI acceptance criteria for flaws exposed to multiple thermal-hydraulic transients. These com-pute-intensive analyses can be carried out with a single execution of FAVOR-OCI. The new methodology determines critical values by solving for either the point of tangency or point of intersection between applied KI versus time histories and a user-selected fracture toughness material property (e.g., ASME KIc, FAVOR Weibull KIc, or Master Curve Weibull KJc) for surface or subsurface flaws. Situations where warm prestress conditions apply can also be addressed. The paper highlights a need for this new capability via applications to a recent independent review of safety cases for RPVs in two Belgian nuclear power plants (NPPs). That review required ASME Section XI assessments of several thousand embedded, quasi-laminar flaws in the wall of each RPV. Analysis results provided by the new capability contributed to the technical bases compiled from several sources by the Belgian nuclear regulatory agency (FANC) and eventually used by FANC to justify the restart of these NPPs.

Dickson, Terry L.↗
DOE OSTI2017

An expert-systems approach to automatically determining flaw depth within Candu pressure tubes - 221

Delayed Hydride Cracking (DHC) is a crack growth mechanism that occurs in zirconium alloys, including the pressure tubes of CANDU reactors. DHC is caused by hydrogen in solution in zirconium components being diffused to any flaws present, resulting in an increased concentration of hydrogen within these flaws. An increased hydrogen concentration can lead to brittleness, followed by cracking, in high-stress regions of a pressure tube. Regular in-service ultrasonic inspection of CANDU pressure tubes aims to locate and classify any flaws that pose a potential for DHC initiation. A common approach to inspection is the use of a bespoke tool containing multiple ultrasonic transducers to ensure that each point on the pressure tube is inspected from a minimum of three angles during a scan. All flaws from within the inspected pressure tubes must be characterized prior to restarting the reactor, thus the time-consuming analysis process lies on the critical outage path. This process is manually intensive and often requires a significant amount of expert knowledge. A modular system to automatically process outage data to provide decision support to analysts has been developed. This system saves time on the critical outage path while providing repeatable and explicable measurements. Part of the analysis process requires the depth of all flaws to be measured, which is often the most time consuming stage of the analysis process. This paper describes an approach that utilizes captured analysts knowledge to perform automatic flaw depth estimation. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Monitoring and flaw detection during wire-based directed energy deposition using in-situ acoustic sensing and wavelet graph signal analysis

The goal of this work is to detect flaw formation in the wire-based directed energy deposition (W-DED) process using in-situ sensor data. The W-DED studied in this work is analogous to metal inert gas electric arc welding. The adoption of W-DED in industry is limited because the process is susceptible to stochastic and environmental disturbances that cause instabilities in the electric arc, eventually leading to flaw formation, such as porosity and suboptimal geometric integrity. Moreover, due to the large size of W-DED parts, it is difficult to detect flaws post-process using non-destructive techniques, such as X-ray computed tomography. Accordingly, the objective of this work is to detect flaw formation in W-DED parts using data acquired from an acoustic (sound) sensor installed near the electric arc. To realize this objective, we develop and apply a novel wavelet integrated graph theory approach. The approach extracts a single feature called graph Laplacian Fiedler number from the noise-contaminated acoustic sensor data, which is subsequently tracked in a statistical control chart. Using this approach, the onset of various types of flaws are detected with a false alarm rate less-than 2%. This work demonstrates the potential of using advanced data analytics for in-situ monitoring of W-DED.

42 ENGINEERING↗
DOE OSTI2020

Multimodal Deep Learning for Flaw Detection in Software Programs

We explore the use of multiple deep learning models for detecting flaws in software programs. Current, standard approaches for flaw detection rely on a single representation of a software program (e.g., source code or a program binary). We illustrate that, by using techniques from multimodal deep learning, we can simultaneously leverage multiple representations of software programs to improve flaw detection over single representation analyses. Specifically, we adapt three deep learning models from the multimodal learning literature for use in flaw detection and demonstrate how these models outperform traditional deep learning models. We present results on detecting software flaws using the Juliet Test Suite and Linux Kernel.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2013

Predicting Flaw-Induced Resonance Spectrum Shift with Theoretical Perturbation Analysis

Resonance inspection is an emerging non-destructive evaluation (NDE) technique which uses the resonance spectra differences between the good part population and the flawed parts to identify anomalous parts. It was previously established that finite-element (FE)-based modal analysis can be used to predict the resonance spectrum for an engineering scale part with relatively good accuracy. However, FE-based simulations can be time consuming in examining the spectrum shifts induced by all possible structural flaws. This paper aims at developing a computationally efficient perturbation technique to quantify the frequency shifts induced by small structural flaws, based on the FE simulated resonance spectrum for the perfect part. A generic automotive connecting rod is used as the example part for our study. The results demonstrate that the linear perturbation theory provides a very promising way in predicting frequency changes induced by small structural flaws. As the flaw size increases, the discrepancy between the perturbation analysis and the actual FE simulation results increases due to nonlinearity, yet the perturbation analysis is still able to predict the right trend in frequency shift.

Acoustics↗
DOE OSTI2016

Probabilistic Fracture Mechanics of Reactor Pressure Vessels with Populations of Flaws

This report documents recent progress in developing a tool that uses the Grizzly and RAVEN codes to perform probabilistic fracture mechanics analyses of reactor pressure vessels in light water reactor nuclear power plants. The Grizzly code is being developed with the goal of creating a general tool that can be applied to study a variety of degradation mechanisms in nuclear power plant components. Because of the central role of the reactor pressure vessel (RPV) in a nuclear power plant, particular emphasis is being placed on developing capabilities to model fracture in embrittled RPVs to aid in the process surrounding decision making relating to life extension of existing plants. A typical RPV contains a large population of pre-existing flaws introduced during the manufacturing process. The use of probabilistic techniques is necessary to assess the likelihood of crack initiation at one or more of these flaws during a transient event. This report documents development and initial testing of a capability to perform probabilistic fracture mechanics of large populations of flaws in RPVs using reduced order models to compute fracture parameters. The work documented here builds on prior efforts to perform probabilistic analyses of a single flaw with uncertain parameters, as well as earlier work to develop deterministic capabilities to model the thermo-mechanical response of the RPV under transient events, and compute fracture mechanics parameters at locations of pre-defined flaws. The capabilities developed as part of this work provide a foundation for future work, which will develop a platform that provides the flexibility needed to consider scenarios that cannot be addressed with the tools used in current practice.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗