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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Nondestructive Evaluation of Stress Corrosion Cracking in a Welded Steel Plate Using Guided Ultrasonic Waves

Stress corrosion cracking (SCC) had occurred in early-generation high-level nuclear waste tanks constructed by welding carbon steel. This paper describes an ultrasonic inspection system and its fundamental ability to detect and quantify the length of SCC on thick welded steel plates. The finite element method (FEM) was applied to simulate the welding process to estimate the welding residual stress field. Growth of stress corrosion cracks is driven by crack stress intensities exceeding the subcritical cracking threshold intensity. The subject plate was experimentally inspected with ultrasonic nondestructive evaluation (NDE) techniques to characterize the extent of SCC. The NDE system uses a piezoelectric transducer to generate guided waves in the thick steel plate, and a scanning laser Doppler vibrometer (SLDV) to measure multidimensional time–space wavefield data over a user-defined scanning area in the plate surface. The measured wavefield data can show wave interactions in a localized area in the plate due to the presence of the discontinuities of the SCC. To generate an inspection image that can precisely show the crack’s location and/or the dimension, the wavefield data are further processed to generate inspection image that maps the entire sample plate so the crack can be clearly identified in the plate while its length can be readily estimated. In conclusion, the ultrasonic test results for crack length agree well with the visually estimated length and are close to that predicted by the FEM for cracks in the weld residual stress field.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Validation and demonstration of the AEFC as a practical safeguards tool for inventory verification

The Advanced Experimental Fuel Counter (AEFC) is a nondestructive assay (NDA) instrument designed to determine the residual fissile mass in irradiated fuel assemblies for safeguards verification purposes. This is done by actively interrogating an assembly with a neutron source and measuring the total (Singles) and correlated (Doubles) neutron count rates resulting from induced fissions in the irradiated nuclear fuel and relating those rates to the residual fissile mass using calibration curves. Comprehensive NDA measurements of the irradiated fuel inventory at Israeli Research Reactor 1 (IRR-1) were taken with the AEFC to validate a set of previously developed calibration curves. During the campaign, measurements were acquired of 32 standard fuel assemblies and three control assemblies in just nine days. This is a significant majority of the research reactor's irradiated fuel inventory and the largest data set gathered by the AEFC to date. Many of the fuel assemblies measured during the campaign had much shorter cooling times than those assemblies previously measured with the instrument. Calibration curves developed from previous AEFC deployments were used to determine the residual 235 U mass in the measured standard fuel assemblies. The results of the campaign demonstrated that the AEFC can be used to estimate the 235 U mass remaining in a large number of irradiated fuel assemblies with 1%–5% uncertainty in a reasonable amount of time despite operating in a high dose environment.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2024

Synchrotron small-angle X-ray scattering technique for battery electrode study

Structure dependent stability is a concern for the achievement of high energy density electrode with long cycling lifetime, especially for alloying-type and conversion-type anodes. Substantial alterations in volume upon discharge-discharge process leads to particle pulverization and continuous consumption of electrolyte. Moreover, the nucleation and growth mechanism of Li 2 O and Li 2 S, which determines the rate performance of Li-O 2 and Li-S batteries, are still understudy. Microstructure characterization techniques have been applied to disclose the structural changes of active material at different charge/discharge states. Synchrotron small-angle X-ray scattering (SAXS) attracts considerable attention because of the high flux, high time resolution and nondestructive characteristics. In addition, SAXS patterns provide statistics structural information of electrode at micrometer scale. The commonly used coin cell with punched holes simplifies the application of in situ/operando SAXS measurement. Here, this review discusses the research about the SAXS technique in the characterization of electrode in different batteries.

25 ENERGY STORAGE↗
DOE OSTI2022

DEFECT DETECTION USING DYNAMIC ANALYSIS FOR ADDITIVE MANUFACTURED METALS

Additive manufacturing (AM) has the ability to produce parts with complex geometries and internal features, however, for demanding applications such as the automotive and aerospace industries, it is crucial that the parts can meet the demanding functional and geometric requirements. Quality control for AM parts focuses on nondestructive methods of testing, but many of the current methods are expensive and time-consuming. The research presented in this report explores various methods of nondestructive evaluation (NDE) using dynamic analysis on stainless steel parts produced with selective laser melting (SLM). Methods include, but are not limited to, frequency response functions (FRF), impedance-based measurements, and scanning laser doppler vibrometry. Additionally, mode shape analysis was performed in MATLAB and FEA simulations were used for comparison with experimental results. The results indicate that dynamic analysis has the potential to be a feasible method of defect detection and NDE in AM parts and future work should focus on refining these methods, such as optimizing test parameters to improve sensitivity to defects.

Deonarain, Gita↗
NASA NTRS2013

Summary of Activities for Health Monitoring of Composite Overwrapped Pressure Vessels

This three-year project (FY12-14) will design and demonstrate the ability of new Magnetic Stress Gages for the measurement of stresses on the inner diameter of a Composite Overwrapped Pressure Vessel overwrap. The sensors are being tested at White Sands Testing Facility (WSTF) where the results will be correlated with a known nondestructive technique acoustic emission. The gages will be produced utilizing Meandering Winding Magnetometer (MWM) and/or MWM array eddy current technology. The ultimate goal is to utilize this technology for the health monitoring of Composite Overwrapped Pressure Vessels for all future flight programs. The first full-scale pressurization test was performed at WSTF in June 2012. The goals of this test were to determine adaptations of the magnetic stress gauge instrumentation that would be necessary to allow multiple sensors to monitor the vessel's condition simultaneously and to determine how the sensor response changes with sensor selection and orientation. The second full scale pressurization test was performed at WSTF in August 2012. The goals of this test were to monitor the vessel's condition with multiple sensors simultaneously, to determine the viability of the multiplexing units (MUX) for the application, and to determine if the sensor responses in different orientations are repeatable. For both sets of tests the vessel was pressured up to 6,000 psi to simulate maximum operating pressure. Acoustic events were observed during the first pressurization cycle. This suggested that the extended storage period prior to use of this bottle led to a relaxation of the residual stresses imparted during auto-frettage. The pressurization tests successfully demonstrated the use of multiplexers with multiple MWM arrays to monitor a vessel. It was discovered that depending upon the sensor orientation, the frequencies, and the sense element, the MWM arrays can provide a variety of complementary information about the composite overwrapped pressure vessel load conditions. For example, low frequency measurements can be used to monitor the overwrap thickness and changes associated with pressure level. High frequency data is dominated by the properties of the overwrap, including the fiber orientations and lay-up of the layers.

Russell, Rick↗
NASA NTRS2005

Infrared On-Orbit Inspection of Shuttle Orbiter Reinforced Carbon-Carbon Using Solar Heating

Thermographic nondestructive inspection techniques have been shown to provide quantitative, large area damage detection capabilities for the ground inspection of the reinforced carbon-carbon (RCC) used for the wing leading edge of the Shuttle orbiter. The method is non-contacting and able to inspect large areas in a relatively short inspection time. Thermal nondestructive evaluation (NDE) inspections have been shown to be applicable for several applications to the Shuttle in preparation for return to flight, including for inspection of RCC panels during impact testing, and for between-flight orbiter inspections. The focus of this work is to expand the capabilities of the thermal NDE methodology to enable inspection by an astronaut during orbital conditions. The significant limitations of available resources, such as weight and power, and the impact of these limitations on the inspection technique are discussed, as well as the resultant impact on data analysis and processing algorithms. Of particular interest is the impact to the inspection technique resulting from the use of solar energy as a heat source, the effect on the measurements due to working in the vacuum of space, and the effect of changes in boundary conditions, such as radiation losses seen by the material, on the response of the RCC. The resultant effects on detectability limits are discussed. Keywords: Nondestructive Evaluation, Shuttle, on-orbit inspection, thermography, infrared

Howell, P. A.↗
DOE OSTI2024

Materials Characterization, Prediction, and Control Project: Characterization of 316L Stainless Steel after Solid Phase Processing using Ultrasonic NDE Method

The Pacific Northwest National Laboratory undertook the Materials Characterization, Prediction, and Control Laboratory Directed Research and Development Project to advance understanding of nuclear material processing and enable multifold acceleration in the development and qualification of new material systems produced via advanced manufacturing methods, such as solid phase processing, for use in national security and advanced energy applications (Smith 2021). A motivation of the Materials Characterization, Prediction, and Control Project was to demonstrate ultrasonic testing as a nondestructive evaluation method to complement traditional destructive methods for characterizing material microstructure with emphasis on grain size determination using a method that may have future applications for real-time inline process monitoring. The objective of the work described in this report is to establish the process and an analysis method for measuring grain sizes of polycrystalline metals with ultrafine grains using ultrasonic shear wave backscattering, building on prior studies on coarser-grained material. The work involves five tasks: Measured ultrasonic backscattering experimentally for a series of 316L stainless steel specimens with various grain sizes made by friction stir processing. Calculated ultrasonic backscattering coefficients from experimental data based on a physical measurement model. Measured ground truth grain sizes of the specimens from electron backscatter diffraction grain boundary images using a generalization of the ASTM E112 (ASTM 2021) intercept method. Built a curve of ultrasonic backscattering coefficients versus the ground truth intercept-based grain sizes to determine the correlation between mean grain sizes and ultrasonic measurements. Demonstrated the ability of using the correlation curve to deduce grain sizes with measured ultrasonic backscattering coefficients for a few 316L stainless steel specimens whose grain sizes were unknown beforehand but were targeted to be an extrapolation to larger grain sizes than used to formulate the correlation curves. Experimental procedures and computational algorithms are developed and validated for these tasks. This work establishes an ultrasonic technique for characterizing material microstructure with ultrafine grains that are often resulted by solid-phase processing. The technique is nondestructive, and it has the potential to be used for real time inline process monitoring. This work successfully demonstrates the viability of an ultrasonic nondestructive evaluation method for microstructural characterization of material having ultrafine grain structure (as small as 1?mm) and produced by an advanced manufacturing method. This includes a demonstration of the method to extrapolate to other conditions. While not demonstrated here, the method is expected to be viable for in-line, or near-inline, process monitoring in advanced manufacturing applications with suitable consideration for access of instrumentation to the material being manufactured.

316 L Stainless Steel↗
DOE OSTI2024

Anti-reflection coating with mullite and Duroid for large-diameter cryogenic sapphire and alumina optics

We developed a broadband two-layer anti-reflection (AR) coating for use on a sapphire half-wave plate (HWP) and an alumina infrared (IR) filter for the cosmic microwave background (CMB) polarimetry. Measuring the faint CMB B-mode signals requires maximizing the number of photons reaching the detectors and minimizing spurious polarization due to reflection with an off-axis incident angle. Sapphire and alumina have high refractive indices of 3.1 and are highly reflective without an AR coating. This paper presents the design, fabrication, quality control, and measured performance of an AR coating using thermally sprayed mullite and Duroid 5880LZ. This technology enables large optical elements with diameters of 600 mm. We also present a thermography-based nondestructive quality control technique, which is key to assuring good adhesion and preventing delamination when thermal cycling. We demonstrate the average reflectance of about 2.6% (0.9%) for two observing bands centered at 90/150 (220/280) GHz. At room temperature, the average transmittance of a 105 mm square test sample at 220/280 GHz is 83%, and it will increase to 90% at 100 K, attributed to reduced absorption losses. Therefore, our developed layering technique has proved effective for 220/280 GHz applications, particularly in addressing dielectric loss concerns. This AR coating technology has been deployed in the cryogenic HWP and IR filters of the Simons Array and the Simons observatory experiments and applies to future experiments such as CMB-S4.

Sakaguri, Kana (ORCID:0000000156678118)↗
NASA NTRS1990

Thermographic inspection of solid-fuel rocket booster field joint components

Thermographic nondestructive evaluation techniques were investigated for possible application on Space Shuttle solid rocket booster field joint hardware. This investigation included evaluation of the clevis and tang mating surfaces for scratches and measurement of grease film thickness. The field joint insulation system was inspected for voids and disbonds.

Thompson, Karen G.↗
NASA NTRS1994

Thermalite Apparatus

Thermalite is portable apparatus that nondestructively determines thermal-diffusion properties of specimen. Based on heat-pulse method; it applies pulse of heat to specimen, then computes relevant thermal properties of specimen from time-resolved measurements of thermal response of specimen to heat pulse. Apparatus is self-contained and calibrated and tested with stored thermal pattern as standard. Used to assess flaw in specimen.

Heyman, Joseph S.↗
DOE OSTI2021

Root water uptake of biofuel crops revealed by coupled electrical resistivity and soil water content measurements

Abstract Biofuel crops, including annuals such as maize ( Zea mays L.), soybean [ Glycine max (L.) Merr.], and canola ( Brassica napus L.), as well as high‐biomass perennial grasses such as miscanthus ( Miscanthus × giganteus J.M. Greef & Deuter ex Hodkinson & Renvoiz), are candidates for sustainable alternative energy sources. However, large‐scale conversion of croplands to perennial biofuel crops could have substantial impacts on regional water, nutrient, and C cycles due to the longer growing seasons and differences in rooting systems compared with most annual crops. However, due to the limited tools available to nondestructively study the spatiotemporal patterns of root water uptake in situ at field scales, these differences in crop water use are not well known. Geophysical imaging tools such as electrical resistivity (ER) reveal changes in water content in the soil profile. In this study, we demonstrate the use of a novel coupled hydrogeophysical approach with both time domain reflectometry soil water content and ER measurements to compare root water uptake and soil properties of an annual crop rotation with the perennial grass miscanthus, across three growing seasons (2009–2011) in southwest Michigan, USA. We estimated maximum root depths to be between 1.2 and 2.2 m, with the vertical distribution of roots being notably deeper in 2009 relative to 2010 and 2011, likely due to the drought conditions during that first year. Modeled cumulative ET of both crops was underestimated (2–34%) relative to estimates obtained from soil water drawdown in prior studies but was found to be greater in the perennial grass than the annual crops, despite shallower modeled rooting depths in 2010 and 2011.

Kuhl, Alexandria S.↗
NASA NTRS1986

Ultrasonic nondestructive materials characterization

A brief review of ultrasonic wave propagation in solid materials is presented with consideration of the altered behavior in anisotropic and nonlinear elastic materials in comparison with isotropic and linear elastic materials. Some experimental results are described in which ultrasonic velocity and attenuation measurements give insight into materials microstructure and associated mechanical properties. Recent developments with laser beam non-contact generation and detection of ultrasound are presented. The results of several years of experimental measurements using high-power ultrasound are discussed, which provide substantial evidence of the inability of presently accepted theories to fully explain the interaction of ultrasound with solid materials. Finally, a special synchrotron X-ray topographic system is described which affords the possibility of observing direct interaction of ultrasonic waves with the microstructural features of real crystalline solid materials for the first time.

Green, R. E., Jr.↗
NASA NTRS1991

Behavior Of NbSe3 Cathode In Rechargeable Li Cell

Report discusses series of ac impedance measurements of niobium triselenide cathodes in lithium secondary (rechargeable) cells. Reported work done to improve understanding of intercalation of NbSe3 with Li and to find out whether state of charge of NbSe3 determined nondestructively from impedance parameters. Authors conclude impedance parameters of NbSe3 do not vary in sufficiently regular fashion to be useful as indicators of state of charge.

Bugga, Ratnakumar V.↗
NASA NTRS1992

Development of a High Resolution Liquid Xenon Imaging Telescope for Medium Energy Gamma Ray Astrophysics

In the third year of the research project, we have (1) tested a 3.5 liter prototype of the Liquid Xenon Time Projection Chamber, (2) used a prototype having a 4.4 cm drift gap to study the charge and energy resolution response of the 3.5 liter chamber, (3) obtained an energy resolution as good as that previously measured by us using chambers with drift gaps of the order of millimeters, (4) observed the induction signals produced by MeV gamma rays, (4) used the 20 hybrid charge sensitive preamplifiers for a nondestructive readout of the electron image on the induction wires, (5) performed extensive Monte Carlo simulations to obtain results on efficiency, background rejection capability, and source flux sensitivity, and (6) developed a reconstruction algorithm for events with multiple interaction points.

Aprile, Elena↗
NASA NTRS2000

Assessment and Assurance of Microelectronics Packaging Technology of Microelectromechanical Systems (MEMS)

Microelectromechanical systems (MEMS) have shown a significant promise in the last decade for a variety of applications such as air-bag, pressure sensors, accelerometer, microgyro, etc. Standard semiconductor microelectronics packaging needs the integrated circuits to be protected from the harsh environment, and provide electrical communication with the other parts of the circuit, facilitate thermal dissipation efficiently, and impart mechanical strength to the silicon die. Microelectronics packaging involves wafer dicing, bonding, lead attachment, encapsulation to protect from the environment, electrical integrity, and package leak tests to assure the packaging technology. In the case of MEMS the microstructures (active elements) often interfaces with the hostile environment where packaging leak tests and testing of such devices using chemical and mechanical parameters will be very difficult and expensive. Packaging of MEMS is significantly complex as they serve to protect from the environment and microstructures interact with the same environment to measure or affect the desired physical or chemical parameters. The most of the silicon circuitry is sensitive to temperature, moisture, magnetic field, light, and electromagnetic interference. The package must then protect the on-board silicon circuitry while simultaneously exposing the microsensor to the effect it 'measures to assure the MEMS technology by lowering the risk to zero. MEMS technology has a major application in developing a microspacecraft for space systems provided assurance of MEMS technology is sufficiently addressed nondestructively. This technology would eventually miniaturize many of the components of the spacecraft to reach the NASA's safety and mission assurance goal by building faster, cheaper, better, smaller spacecraft to explore the space more effectively by teaming-up with the other NASA centers using the limited resources available. This paper discusses the latest developments in the MEMS technology and challenging issues in the packaging of hermetically sealed and non-hermetically sealed MEMS sensor devices based on silicon, poly-silicon, and other materials for microspacecraft applications considering the space environment and reliability assurance qualification guidelines in perspective. Acknowledgments: The above research work is supported by the NASA Electronics Parts and Packaging Program (NEPP) and performed by the Jet Propulsion Laboratory, California Institute of Technology, Pasadena, CA under a contract with the NASA - Code Q for the Office of Safety and Mission Assurance Program 323-79.

Ramesham, Rajeshuni↗
NASA NTRS2002

Ultrasonic Characterization of Fatigue Cracks in Composite Materials

Microcracking in composite structures due to combined fatigue and cryogenic loading can cause leakage and failure of the structure and can be difficult to detect in-service. In aerospace systems, these leaks may lead to loss of pressure/propellant, increased risk of explosion and possible cryo-pumping. The success of nondestructive evaluation to detect intra-ply microcracking in unlined pressure vessels fabricated from composite materials is critical to the use of composite structures in future space systems. The work presented herein characterizes measurements of intraply fatigue cracking through the thickness of laminated composite material by means of correlation with ultrasonic resonance. Resonant ultrasound spectroscopy provides measurements which are sensitive to both the microscopic and macroscopic properties of the test article. Elastic moduli, acoustic attenuation, and geometry can all be probed. The approach is based on the premise of half-wavelength resonance. The method injects a broadband ultrasonic wave into the test structure using a swept frequency technique. This method provides dramatically increased energy input into the test article, as compared to conventional pulsed ultrasonics. This relative energy increase improves the ability to measure finer details in the materials characterization, such as microcracking and porosity. As the microcrack density increases, more interactions occur with the higher frequency (small wavelength) components of the signal train causing the spectrum to shift toward lower frequencies. Several methods are under investigation to correlate the degree of microcracking from resonance ultrasound measurements on composite test articles including self organizing neural networks, chemometric techniques used in optical spectroscopy and other clustering algorithms.

Workman, Gary L.↗
NASA NTRS1978

Corrosion detection and evaluation

Report details comprehensive study of nondestructive methods for detecting and/or evaluating up to six different types of corrosion: general, galvanic filiform, pitting, intergranular, and stress. Studied methods include: visual/optical inspection, radiography, penetrant inspection, analysis by polarized light, electrical conductivity measurements, pH analysis, and ultrasonic inspection.

Kammerer, C. C.↗