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NASA NTRS2005

Implementing Recommendations of the Columbia Accident Investigation Board: Development of On-Orbit IR Thermography

One of NASA's Space Shuttle Return-to-Flight (RTF) efforts has been to develop thermography for the on-orbit inspection of the Reinforced Carbon Carbon (RCC) portion of the Orbiter Wing Leading Edge (WLE). This paper addresses the capability of thermography to detect cracks in RCC by using in-plane thermal gradients that naturally occur on-orbit. Crack damage, which can result from launch debris impact, is a detection challenge for other on-orbit sensors under consideration for RTF, such as the Intensified Television Camera and Laser Dynamic Range Imager. We studied various cracks in RCC, both natural and simulated, along with material characteristics, such as emissivity uniformity, in steady-state thermography. Severity of crack, such as those likely and unlikely to cause burn through were tested, both in-air and in-vacuum, and the goal of this procedure was to assure crew and vehicle safety during reentry by identification and quantification of a damage condition while on-orbit. Expected thermal conditions are presented in typical shuttle orbits, and the expected damage signatures for each scenario are presented. Finally, through statistical signal detection, our results show that even at very low in-plane thermal gradients, we are able to detect damage at or below the threshold for fatality in the most critical sections of the WLE, with a confidence exceeding 1 in 10,000 probability of false negative.

Ottens, Brian P.↗

NASA NTRS2010

IR Thermography NDE of ISS Radiator Panels

The presentation covers an active and a passive infrared (IR) thermography for detection of delaminations in the radiator panels used for the International Space Station (ISS) program. The passive radiator IR data was taken by a NASA astronaut in an extravehicular activity (EVA) using a modified FLIR EVA hand-held camera. The IR data could be successfully analyzed to detect gross facesheet disbonds. The technique used the internal hot fluid tube as the heat source in analyzing the IR data. Some non-flight ISS radiators were inspected using an active technique of IR flash thermography to detect disbond of face sheet with honeycomb core, and debonds in facesheet overlap areas. The surface temperature and radiated heat emission from flight radiators is stable during acquisition of the IR video data. This data was analyzed to detect locations of unexpected surface temperature gradients. The flash thermography data was analyzed using derivative analysis and contrast evolutions. Results of the inspection are provided.

Koshti, Ajay↗

NASA NTRS2010

Exit Presentation: Infrared Thermography on Graphite/Epoxy

This slide presentation reports on the internship project that was accomplished during the summer of 2010. The objectives of the project were to: (1) Simulate Flash Thermography on Graphite/Epoxy Flat Bottom hole Specimen and thin void specimens, (2) Obtain Flash Thermography data on Graphite/Epoxy flat bottom hole specimens, (3) Compare experimental results with simulation results, Compare Flat Bottom Hole Simulation with Thin Void Simulation to create a graph to determine size of IR Thermography detected defects

Comeaux, Kayla↗

NASA NTRS2011

Thermography to Inspect Insulation of Large Cryogenic Tanks

Thermography has been used in the past to monitor active, large, cryogenic storage tanks. This approach proposes to use thermography to monitor new or refurbished tanks, prior to filling with cryogenic liquid, to look for insulation voids. Thermography may provide significant cost and schedule savings if voids can be detected early before a tank is returned to service.

Arens, Ellen↗

NASA NTRS2014

Infrared Contrast Analysis Technique for Flash Thermography Nondestructive Evaluation

The paper deals with the infrared flash thermography inspection to detect and analyze delamination-like anomalies in nonmetallic materials. It provides information on an IR Contrast technique that involves extracting normalized contrast verses time evolutions from the flash thermography infrared video data. The paper provides the analytical model used in the simulation of infrared image contrast. The contrast evolution simulation is achieved through calibration on measured contrast evolutions from many flat bottom holes in the subject material. The paper also provides formulas to calculate values of the thermal measurement features from the measured contrast evolution curve. Many thermal measurement features of the contrast evolution that relate to the anomaly characteristics are calculated. The measurement features and the contrast simulation are used to evaluate flash thermography inspection data in order to characterize the delamination-like anomalies. In addition, the contrast evolution prediction is matched to the measured anomaly contrast evolution to provide an assessment of the anomaly depth and width in terms of depth and diameter of the corresponding equivalent flat-bottom hole (EFBH) or equivalent uniform gap (EUG). The paper provides anomaly edge detection technique called the half-max technique which is also used to estimate width of an indication. The EFBH/EUG and half-max width estimations are used to assess anomaly size. The paper also provides some information on the "IR Contrast" software application, half-max technique and IR Contrast feature imaging application, which are based on models provided in this paper.

Koshti, Ajay↗

NASA NTRS2018

Detection of Damage During Quasi-Static Loading of a Single Stringer Panel Using Passive Thermography and Acoustic Emission

The purpose of this paper is to describe the methodology of measuring damage onset and growth in a composite structure during quasi-static loading using passive thermography and acoustic emission. 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 resulted in the formation of damage between the stiffener flange and skin. The loading was stopped when damage growth was detected. Passive thermography and acoustic emission were used to detect damage in real-time as a function of the applied load. Of particular interest are the small transient thermographic signals resulting from damage formation which can be challenging to detect, as compared to the persistent passive thermography indications of cyclic fatigue loading. We describe a custom developed thermal inspection system for detection of composite damage during quasi-static loading. The thermal results are compared to a two-dimensional multi-layered thermal simulation based on the quadrupole method. Acoustic emission is used to further characterize the damage by comparing the acoustic emission events with the thermal imagery. Results are compared to ultrasonic measurements to document the damage through-the-thickness.

Zalameda, Joseph N.↗

NASA NTRSDate not supplied

Active Thermography Based on Tensor Rank Decomposition

Principal Component Thermography applies Singular Value Decomposition (SVD) to post-process data that are derived from active thermographic inspections. SVD provides useful compression of the data and allows for better understanding of substructure and indications of potential damage. In the standard approach, SVD is applied to a certain reshaping of a three-dimensional data stack into a two-dimensional array. This work applies the CANDECOMP-PARAFAC (CP) tensor rank decomposition directly to the three-dimensional data to avoid the initial reshaping step in order to begin to develop an inspection method that can more accurately detect defects in non-homogeneous and anisotropic materials. Tests against simulated data that compare the CP decomposition method with traditional Principal Component Thermography based on SVD are described. Finally, the method of Proper Generalized Decomposition (PGD) is used to derive the CP decomposition, and its performance against other algorithms is also discussed.

Thermography↗

NASA NTRSDate not supplied

Composite Bond Line Measurements Based on A Bayesian Analysis of Flash Thermography Data

For bonded composite materials, an accurate characterization of the adhesive bond line is needed to predict failure modes and fracture toughness. In this paper, bond line thickness was estimated from data obtained using through transmission flash thermography. The forward model that predicts back surface temperature is based on a three layer heat diffusion equation with varying diffusivity and flux boundary conditions. The corresponding inverse problem of estimating bond line thickness from measurement data was solved using a Bayesian approach that assumed Gaussian priors for the bond line thickness and thermal diffusivity of the adherends. Finally, the outputs of the thermography based method were compared to measurements that were collected using a micrometer and ultrasound testing.

Flash thermography↗

NASA NTRSDate not supplied

Composite Bond Line Measurements Based on a Bayesian Analysis of Flash Thermography Data

Flash thermography↗

NASA NTRS1981

Reliable aerial thermography for energy conservation

A method for energy conservation, the aerial thermography survey, is discussed. It locates sources of energy losses and wasteful energy management practices. An operational map is presented for clear sky conditions. The map outlines the key environmental conditions conductive to obtaining reliable aerial thermography. The map is developed from defined visual and heat loss discrimination criteria which are quantized based on flat roof heat transfer calculations.

Jack, J. R.↗

NASA NTRS1989

Aerodynamic applications of infrared thermography

A series of wind tunnel experiments were conducted as part of a systematic study for evaluation of infrared thermography as a viable non-intrusive thermal measurement technique for aerodynamic applications. The experiments consisted of obtaining steady-state surface temperature and convective heat transfer rates for a uniformly heated cylinder in transverse flow with a Reynolds number range of 46,000 to 250,000. The calculated convective heat transfer rates were in general agreement with classical data. Furthermore, IR thermography provided valuable real-time fluid dynamic information such as visualization of flow separation, transition and vortices.

Daryabeigi, Kamran↗

NASA NTRS1991

A relative-intensity two-color phosphor thermography system

The NASA LaRC has developed a relative-intensity two-color phosphor thermography system. This system has become a standard technique for acquiring aerothermodynamic data in LaRC Hypersonic Facilities Complex (HFC). The relative intensity theory and its application to the LaRC phosphor thermography system is discussed along with the investment casting technique which is critical to the utilization of the phosphor method for aerothermodynamic studies. Various approaches to obtaining quantitative heat transfer data using thermographic phosphors are addressed and comparisons between thin-film data and thermographic phosphor data on an orbiter-like configuration are presented. In general, data from these two techniques are in good agreement. A discussion is given on the application of phosphors to integration heat transfer data reduction techniques (the thin film method) and preliminary heat transfer data obtained on a calibration sphere using thin-film equations are presented. Finally, plans for a new phosphor system which uses target recognition software are discussed.

Merski, N. Ronald↗

NASA NTRS1996

Endoscopic Shearography and Thermography Methods for Nondestructive Evaluation of Lined Pressure Vessels

The goal of this research effort was the development of methods for shearography and thermography inspection of coatings, bonds, or laminates inside rocket fuel or oxidizer tanks, fuel lines, and other closed structures. The endoscopic methods allow imaging and inspection inside cavities which are traditionally inaccessible with shearography or thermography cameras. The techniques are demonstrated and suggestions for practical application are made in this report. Drawings of the experimental setups, detailed procedures, and experimental data are included.

Lansing, Matthew D.↗

NASA NTRS1997

In-Flight Flow Visualization Using Infrared Thermography

The feasibility of remote infrared thermography of aircraft surfaces during flight to visualize the extent of laminar flow on a target aircraft has been examined. In general, it was determined that such thermograms can be taken successfully using an existing airplane/thermography system (NASA Dryden's F-18 with infrared imaging pod) and that the transition pattern and, thus, the extent of laminar flow can be extracted from these thermograms. Depending on the in-flight distance between the F-18 and the target aircraft, the thermograms can have a spatial resolution of as little as 0.1 inches. The field of view provided by the present remote system is superior to that of prior stationary infrared thermography systems mounted in the fuselage or vertical tail of a subject aircraft. An additional advantage of the present experimental technique is that the target aircraft requires no or minimal modifications. An image processing procedure was developed which improves the signal-to-noise ratio of the thermograms. Problems encountered during the analog recording of the thermograms (banding of video images) made it impossible to evaluate the adequacy of the present imaging system and image processing procedure to detect transition on untreated metal surfaces. The high reflectance, high thermal difussivity, and low emittance of metal surfaces tend to degrade the images to an extent that it is very difficult to extract transition information from them. The application of a thin (0.005 inches) self-adhesive insulating film to the surface is shown to solve this problem satisfactorily. In addition to the problem of infrared based transition detection on untreated metal surfaces, future flight tests will also concentrate on the visualization of other flow phenomena such as flow separation and reattachment.

vanDam, C. P.↗

NASA NTRS2000

Karst Groundwater Hydrologic Analyses Based on Aerial Thermography

On February 23, 1999, thermal imagery of Marshall Space Flight Center, Alabama was collected using an airborne thermal camera. Ground resolution was I in. Approximately 40 km 2 of thermal imagery in and around Marshall Space Flight Center (MSFC) was analyzed to determine the location of springs for groundwater monitoring. Subsequently, forty-five springs were located ranging in flow from a few ml/sec to approximately 280 liter/sec. Groundwater temperatures are usually near the mean annual surface air temperature. On thermography collected during the winter, springs show up as very warm spots. Many of the new springs were submerged in lakes, streams, or swamps; consequently, flow measurements were difficult. Without estimates of discharge, the impacts of contaminated discharge on surface streams would be difficult to evaluate. An approach to obtaining an estimate was developed using the Environmental Protection Agency (EPA) Cornell Mixing Zone Expert System (CORMIX). The thermography was queried to obtain a temperature profile down the center of the surface plume. The spring discharge was modeled with CORMIX, and the flow adjusted until the surface temperature profile was matched. The presence of volatile compounds in some of the new springs also allowed MSFC to unravel the natural system of solution cavities of the karst aquifer. Sampling results also showed that two springs on either side of a large creek had the same water source so that groundwater was able to pass beneath the creek.

Campbell, C. Warren↗

NASA NTRS2009

Application of Air Coupled Acoustic Thermography (ACAT) for Inspection of Honeycomb Sandwich Structures

The application of a noncontact air coupled acoustic heating technique is investigated for the inspection of advanced honeycomb composite structures. A weakness in the out of plane stiffness of the structure, caused by a delamination or core damage, allows for the coupling of acoustic energy and thus this area will have a higher temperature than the surrounding area. Air coupled acoustic thermography (ACAT) measurements were made on composite sandwich structures with damage and were compared to conventional flash thermography. A vibrating plate model is presented to predict the optimal acoustic source frequency. Improvements to the measurement technique are also discussed.

Winfree, William P.↗

NASA NTRS2010

IR Thermography of International Space Station Radiator Panels

Several non-flight qualification test radiators were inspected using flash thermography. Flash thermography data analysis used raw and second derivative images to detect anomalies (Echotherm and Mosaic). Simple contrast evolutions were plotted for the detected anomalies to help in anomaly characterization. Many out-of-family indications were noted. Some out-of-family indications were classified as cold spot indications and are due to additional adhesive or adhesive layer behind the facesheet. Some out-of-family indications were classified as hot spot indications and are due to void, unbond or lack of adhesive behind the facesheet. The IR inspection helped in assessing expected manufacturing quality of the radiators.

Koshti, Ajay↗

NASA NTRS2014

Flash Infrared Thermography Contrast Data Analysis Technique

This paper provides information on an IR Contrast technique that involves extracting normalized contrast versus time evolutions from the flash thermography inspection infrared video data. The analysis calculates thermal measurement features from the contrast evolution. In addition, simulation of the contrast evolution is achieved through calibration on measured contrast evolutions from many flat-bottom holes in the subject material. The measurement features and the contrast simulation are used to evaluate flash thermography data in order to characterize delamination-like anomalies. The thermal measurement features relate to the anomaly characteristics. The contrast evolution simulation is matched to the measured contrast evolution over an anomaly to provide an assessment of the anomaly depth and width which correspond to the depth and diameter of the equivalent flat-bottom hole (EFBH) similar to that used as input to the simulation. A similar analysis, in terms of diameter and depth of an equivalent uniform gap (EUG) providing a best match with the measured contrast evolution, is also provided. An edge detection technique called the half-max is used to measure width and length of the anomaly. Results of the half-max width and the EFBH/EUG diameter are compared to evaluate the anomaly. The information provided here is geared towards explaining the IR Contrast technique. Results from a limited amount of validation data on reinforced carbon-carbon (RCC) hardware are included in this paper.

Koshti, Ajay↗