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At least 379 records · Page 21

Fabrication and Improvement of Lmsc's All-silica RSI

The LI-1500 and LI-900 all silica RSI materials have made the transition from laboratory to manufacturing operation. Improvements in both quality and reproducibility have been achieved. The LI-1500 material has displayed superior reliability in evaluations conducted at various facilities. The dependable performance of the material is attributed to the adherence to the stringent requirements of the numerous material, process, and product control evaluations and inspection points performed during manufacture.

Beasley, R. M.↗

Study Thermographic Flaw Detection

The development of thermographic inspection methods for use on aerospace structures is under investigation. Several different material systems, structural geometries and defect types have been included in this study so as to establish a baseline from which future IRT testing can be made. This study examines various thermal loading techniques in an attempt to enhance the likelihood of capturing and identifying critically sized flaws under 'non-laboratory' actual working conditions. Qualification techniques and calibration standards are also being investigated to standardize the thermographic method. In conjunction with the thermographic inspections, advanced image processing techniques including digital filtering and neural networks have been investigated to increase the ability of 91 detecting and sizing flaws. Here, the digitized thermographic images are mathematically manipulated through various filtering techniques and/or artificial neural mapping schemes to enhance its overall quality, permitting accurate flaw identification even when the signal-to-noise ratio is low.

Walker, James L.↗

Using 2.5D super-resolution to improve flaw detection in metal additive manufacturing parts

Industrial X-ray computed tomography (XCT) enables non-destructive inspection of additively manufactured (AM) parts, but high-resolution scanning requires long acquisition times and significant computational resources, limiting throughput in production environments. Super-resolution techniques can recover high-resolution information from low-resolution scans, but existing methods face a trade-off between 2D approaches that ignore inter-slice information and 3D methods that are computationally prohibitive for practical deployment. To address this trade-off, we propose a 2.5D deep learning-based super-resolution approach that uses seven neighbouring low-resolution slices to super-resolve the centre slice. This work evaluates the method on real XCT scans of steel AM parts, comparing reconstruction quality and flaw detection performance of 2D, 2.5D, and 3D ESRGAN-based super-resolution methods. Results demonstrate that 2.5D super-resolution significantly improves detection of small, process-induced flaws (e.g. porosity) compared to 2D methods, while avoiding the prohibitive computational burden of full 3D approaches. These findings provide initial evidence of 2.5D super-resolution as a practical, deployable solution for improving flaw detection in high-throughput industrial XCT inspection.

X-ray CT↗

Portable Inspection

The portable SpectroReflectometer, an instrument developed by AZ Technology, Inc. in partnership with NASA's Kennedy Space Center is now being manufactured and sold as a cost-effective solution to the development of scientific space flight hardware. This technology originated with the efforts to determine the degradation mechanisms of the space environment on space craft materials. AZ Technology's mission is to provide high quality products and services in electro-mechanical-optical design and hardware integration, advanced thermal and optical coatings and materials, and in the development of custom hardware systems for scientific measurements.

Source record↗

Gulf of Mexico Health & Air Quality: Mapping Methane Emission Plumes Using Sunglint-configured Imagery for Monitoring Offshore Oil and Gas Activity

We had three project objectives that we set out to accomplish. The first objective is to demonstrate how remote sensing can complement the current bottom-up methane emission assessments. Currently, quantities of disposed gas vented and flared are self-reported by operators to BOEM and BSEE. Meanwhile, inspections are uncommon, and ground sensors are non-existent. Therefore, remote sensing may be the agencies' best bet in verifying these operator accounts. The second objective is to identify methane plumes in the Gulf of Mexico, Asia, and elsewhere using Sentinel-2, LandSat, and PRISMA images, and then present an estimate of their emission rate. While methane retrievals from oil and gas infrastructure on-shore has been relatively well-documented, doing so on the offshore oil and gas platforms is more difficult, less prevalent, and contingent on the presence of specific conditions. The final objective is to give our partners, BOEM and BSEE, a more robust understanding of methane emissions from oil and gas production in the Gulf of Mexico. This increased knowledge, paired with a demonstration of methane monitoring, is intended to help our partners think about how they can incorporate remote sensing into their monitoring, regulatory and enforcement framework.

Ben Dahan↗

Optimization of a Welding Procedure for Making Critical Aluminum Welds on the LBNF Absorber Core Block

The LBNF Absorber consists of thirteen 6061-T6 aluminum core blocks. The core blocks are water cooled with de-ionized (DI) water which becomes radioactive during beam operations. The cooling water flows through gun-drilled channels in the core blocks. A weld quality optimization was performed to produce National Aeronautical Standard 1514 Class I quality welds on the aluminum core blocks. This was not successful in all cases. An existing Gas Tungsten Arc Welding Procedure Specification was fine tuned to minimize, in most cases, and eliminate detect-able tungsten inclusions in the welds. All the weld coupons, however passed welding inspection as per the piping code: ASME B31.3 Normal Fluid Service. Tungsten electrode diameter, type, and manufacturer were varied. Some of the samples were pre-heated and others were not. It was observed that larger diameter electrodes, 5/32 in., with pre-heated joints resulted in welds with the least number of tungsten inclusions. It is hypothesized that thinner electrodes breakdown easily and get lodged into the weld pool during the welding process. This breakdown is further enhanced by the large temperature differential between the un-preheated sample and the hot electrode.

43 PARTICLE ACCELERATORS↗

Optimization of a Welding Procedure for Making Critical Aluminum Welds on the LBNF Absorber Core Block

he LBNF Absorber consists of thirteen 6061-T6 aluminum core blocks. The core blocks are water cooled with de-ionized (DI) water which becomes radioactive during beam operations. The cooling water flows through gun-drilled channels in the core blocks. A weld quality optimization was performed to produce National Aeronautical Standard (NAS) 1514 Class I quality welds on the aluminum core blocks. This was not successful in all cases. An existing Gas Tungsten Arc Welding (GTAW) Welding Procedure Specification (WPS) was fine tuned to minimize, in most cases, and eliminate detectable tungsten inclusions in the welds. All the weld coupons however, passed welding inspection as per the piping code: ASME B31.3 Normal Fluid Service. Tungsten electrode diameter, type, and manufacturer were varied. Some of the samples were pre-heated and others were not. It was observed that larger diameter electrodes, 5/32 in., with pre-heated joints resulted in welds with the least number of tungsten inclusions. It is hypothesized that thinner electrodes breakdown easily and get lodged into the weld pool during the welding process. This breakdown is further enhanced by the large temperature differential between the un-preheated sample and the hot electrode.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

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↗

Data processing methods and data acquisition for samples larger than the field of view in parallel-beam tomography

Parallel-beam tomography systems at synchrotron facilities have limited field of view (FOV) determined by the available beam size and detector system coverage. Scanning the full size of samples bigger than the FOV requires various data acquisition schemes such as grid scan, 360-degree scan with offset center-of-rotation (COR), helical scan, or combinations of these schemes. Though straightforward to implement, these scanning techniques have not often been used due to the lack of software and methods to process such types of data in an easy and automated fashion. The ease of use and automation is critical at synchrotron facilities where using visual inspection in data processing steps such as image stitching, COR determination, or helical data conversion is impractical due to the large size of datasets. Here, we provide methods and their implementations in a Python package, named Algotom, for not only processing such data types but also with the highest quality possible. The efficiency and ease of use of these tools can help to extend applications of parallel-beam tomography systems.

36 MATERIALS SCIENCE↗

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.↗

A Conceptual Design and Economic Assessment of a Chitin Biorefinery Based on Shrimp Processing Wastes

Due to the extensive production of shrimp in captivity, waste generation has increased significantly and has become an environmental problem. The recovery of biomolecules can be an important way to mitigate the environmental problems associated with processing in this sector. In this sense, the present work aimed to evaluate a biorefinery approach for valuing shrimp farming waste to obtain astaxanthin, chitin and chitosan. Stoichiometric segmentation was used as a tool to identify the process steps, whose information on process variables (fresh water consumption, flow rate and reaction conditions) was adapted from the literature. A biorefinery coupled to a shrimp processing plant was proposed for the immediate use of highly perishable biomass, to guarantee the quality of the extracted products and reduce storage and transportation costs. In practice, the biomass treatment sequence adopted (demineralization followed by deproteinization) eliminates the depigmentation step, as the chitin obtained has a lighter tone. The proposed route was evaluated for four scenarios based on two indicators: gross economic potential (EGP) and metrics for inspection of sales and reagents (MISR). The results indicate that economic viability is achieved only for the production of chitosan, resulting in a gross revenue of US$832.50/cycle and a MISR value > 1. The sale of astaxanthin promotes an increase of US$3.73/cycle in the EGP, considered too low for the inclusion of another stage in the process.

astaxanthin↗

Double-Shell Tank Primary Bottom Visual Inspection Results - 20025

A pressing need for the Double-Shell Tank Integrity Program at Hanford is of the ability to inspect the bottom of the tanks. Though the DSTs' annulus spaces (the space between the internal and external tank walls) have been inspected visually since 1992 and with Ultrasonic Testing (UT) since 1996, inspections of the tank bottoms have been able to be conducted due to limitations of available technology, omitting about 40 percent of the tank surface below the maximum fill level from routine inspection. Visual inspections of the tank annulus have been conducted up to five times in some DSTs and portions of the annulus space for all of the DSTs has been inspected twice with UT. This region includes the walls of the primary tank and secondary liner along with accessible portions of the secondary liner bottom. Due to this lack of technology, the degradation of the primary tank bottom in Tank AY-102 was undetected until the tank leaked into its annulus space, confirmed in 2012. Since that time, WRPS has been working with the nondestructive examination community and the Pacific Northwest National Laboratory, to evaluate potential technologies to conduct these challenging remote inspections. Recent work has included the development, testing, and deployment of several remote visual inspection technologies to observe the condition of the primary tank bottom of the DSTs by leveraging air distribution slots in the refractory pad on which it rests. Robotic solutions to conduct this inspection were developed with a detailed understanding of the physical configuration and operational logistics. Understanding and subsequent communication of these details to vendors within the robotics and nondestructive examination community was a critical component to the successful production of these new tools. Throughout the FY16-FY18 years, vendors from nondestructive examination community were solicited for ideas to meet the tank bottom inspection challenge. Two tank bottom visual inspection solutions were then pursued to meet that challenge. Both tools were successfully deployed at Tank AP-107, and provided valuable visuals, never before obtained from the under tank environment of a double-shell tank. While there are minor opportunities for improvement identified with each system, general outcomes were overwhelmingly positive. Both systems were successfully able to navigate the refractory air slot pattern from the outer edge to the tank center and record video footage. The micro-crawler provided high quality and very stable footage through the air slot pattern, but took longer to deploy into the slots and traverse through them than the alternative system. The push-pull tethered camera was able to navigate all seven of its target air slots in a matter of a few hours, which included deployment, movement between slot entrances, and complete removal of the system from the annulus environment. Through these air slots, new information was gained about the tank bottom and refractory pad condition of tank AP-107, AP-106, AP-108, and AN-102. While some debris was noted in the air slots, including sand, chipped refractory, and construction materials, the refractory was found to be structurally stable and adequately supporting the primary tank bottom through the full diameter of the tank. Primary tank bottom steel exterior was found to be in good condition, free of ongoing or aggressive corrosion conditions. Looking toward the future, robotic access to and visual inspection of refractory air slots and the primary tank bottom steel has now proven viable. Incorporating periodic air slot inspections as a regular practice within the Double-Shell Tank Integrity Program is the next step, allowing trending of any changes in condition. As ultrasonic testing infrastructure was leveraged to complete the initial system deployments described in this report, it makes sense to adopt that same strategy for ongoing periodic examinations and deploy these primary tank bottom inspection tools alongside ultrasonic testing operations. Development of visual inspection tools to evaluate the primary tank bottom region of the double-shell tanks was planned as the first stage of inspection. Continued development of volumetric sensors and incorporation of these inspection tools into Hanford's ongoing Double-Shell Tank Integrity Program are the next steps, seeking to continuously expand understanding of asset integrity and remaining useful life. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗