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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 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
NASA NTRS2002

NDE of Friction Stir Welds in Aerospace Applications

Friction Stir Welding (FSW) is a solid state joining process, which utilizes a cylindrical, shouldered pin tool with a radiused tip that is rotated and plunged into the weld joint. Frictional heating beneath the shoulder, and surrounding the pin tip causes the material to plasticize, intermix and consolidate into a weldment without melting the parent material. FSW in aluminum alloys has many advantages such as low distortion and shrinkage, excellent mechanical properties, and no porosity. However, the propensity of the FSW process to create detrimental defects does exist, and is dependent on FSW parameter limits and controls. Inspection processes for FSW must also be selected and implemented concurrent with the new weld process. This paper describes the efforts by Lockheed Martin and NASA to find proper NDE techniques for detecting and characterizing the anomalies that may be caused by operating outside the envelope of optimized FSW parameters. Potential defects are identified and the results of the exploration of numerous NDE techniques including visual, liquid penetrant, multiple ultrasonic methods, eddy current and conductivity are discussed.

Kinchen, David G.↗
NASA NTRS2002

Friction Stir Weld Inspection Through Conductivity Imaging Using Shaped Field MWM(Registered Trademark) - Arrays

Friction Stir Welds (FSW) of Al 2195-T8 and Al 2219-T8, provided by Lockheed Martin Michoud Operations, were inspected for lack-of-penetration (LOP) defects using a custom designed MWM-Array, a multi-element eddy-current sensor. MWM (registered trademark) electrical conductivity mapping demonstrated high sensitivity to LOP as small as 0.75 mm (0.03 in.), as confirmed by metallographic data that characterized the extent of LOP defects. High sensitivity and high spatial resolution was achieved via a 37-element custom designed MWM-Array allowing LOP detection using the normalized longitudinal component of the MWM measured conductivity. This permitted both LOP detection and correlation of MWM conductivity features with the LOP defect size, as changes in conductivity were apparently associated with metallurgical features within the near-surface layer of the LOP defect zone. MWM conductivity mapping reveals information similar to macro-etching as the MWM-Array is sensitive to small changes in conductivity due to changes in microstructure associated with material thermal processing, in this case welding. The electrical conductivity measured on the root side of FSWs varies across the weld due to microstructural differences introduced by the FSW process, as well as those caused by planar flaws. Weld metal, i.e., dynamically recrystallized zone (DXZ), thermomechanically affected zone (TMZ), heat-affected zone (HAZ), and parent metal (PM) are all evident in the conductivity maps. While prior efforts had met with limited success for NDE (Nondestructive Evaluation) of dissimilar alloy, Al2219 to Al2195 FSW, the new custom designed multi-element MWM-Array achieved detection of all LOP defects even in dissimilar metal welds.

Goldfine, Neil↗
NASA NTRS1996

Nondestructive Test Probe

Under the Aircraft Structural Integrity program, Langley Research Center invented a device to detect fatigue cracks in aluminum alloy plates. Krautkramer Branson obtained an exclusive license and commercialized a hand-held device, the "CrackFinder," an electromagnetic probe for nondestructive evaluation, used to scan aircraft skins for surface breaks. The technology involves an eddy current, which is an electrical current induced by an alternating magnetic field. The CrackFinder also employs an innovative self-nulling feature, where the device automatically recalibrates to zero so that each flaw detected produces a reading. Compared to conventional testing systems, the CrackFinder is affordable, small, simple to use, and needs no calibration.

Source record↗
NASA NTRS2003

Magnetic Bearing Controller Improvements for High Speed Flywheel System

A magnetic bearing control system for a high-speed flywheel system is described. The flywheel utilizes a five axis active magnetic bearing system, using eddy current sensors for position feedback to the bearing controller. Magnetic bearing controller features designed to improve flywheel operation and testing are described. Operational improvements include feed forward control to compensate for rotor imbalance, moving notch filtering to compensate for synchronous and harmonic rotational noise, and fixed notching to prevent rotor bending mode excitation. Testing improvements include adding safe gain, bearing current hold, bearing current zero, and excitation input features. Performance and testing improvements provided by these features are measured and discussed.

Dever, Timothy P.↗
NASA NTRS2003

Qualifying the Sunpower M87N Cryocooler for Operation in the AMS-02 Magnetic Field

The Alpha Magnetic Spectrometer-02 (AMs-02) experiment uses a superfluid helium dewar to cool a large superconducting magnet. The outer vapor-cooled shields of the dewar are to be held at 80 K by four Sunpower M87N cryocoolers. These cryocoolers have magnetic components that might interact with the external applied field generated by the superconducting magnet, thereby degrading the cryocoolers' performance. Engineering models of the Sunpower M87 have been qualified for operation in a magnetic environment similar to the AMs-02 magnetic environment. Although there was no noticeable performance degradation at field levels that were comparable to AMs-02 field levels, there appears to be a small performance degradation at higher field levels. It was theorized that there were three possible issues related to these performance losses at high magnetic fields: i) induced piston rubbing on the cylinder wall due to forces and torques on the linear motor due to the applied magnetic fields; ii) Magnetic hysteretic and/or eddy current damping of the balancer due to its motion in the applied magnetic fields; iii) Inductance losses in motor due to the applied magnetic field. The experiments conducted at the Massachusetts Institute of Technology (MIT) cyclotron facility in June 2002 were designed to test these. Tests were performed over a range of field levels that were lower, comparable, and higher than the field levels that the cryocoolers will experience in the AMs-02 operating environment. This paper describes the experiments and the inferences derived from them.

Mustafi, Shuvo↗
NASA NTRS2003

Low Temperature SQUID for NDE Applications

We have developed a low temperature SuperConducting Quantum Interference Device - SQUID measurement system for detection of defects deep under the surface of aluminum structures using eddy current techniques. The system uses a two dimensional planar inducer with two different excitation frequencies to induce a current in the sample. We have developed a data analysis software program that enabled us to distinguish between round defects (holes), straight defects (slots) and slots close to holes simulating cracks starting from rivets in aluminum structures. We were able to detect defects that are 8mm below the surface. We have also measured the change in phase of the detected signal as a function of depth of the defect. This relationship can be used to determine the depth of hidden flaws. Using this analysis software with the high temperature SQUID system at NASA Langley we were able to detect slots close to holes in layered aluminum sample.

Wincheski, Buzz↗
NASA NTRS2004

Thrust Stand for Electric Propulsion Performance Evaluation

An electric propulsion thrust stand capable of supporting thrusters with total mass of up to 125 kg and 1 mN to 1 N thrust levels has been developed and tested. The mechanical design features a conventional hanging pendulum arm attached to a balance mechanism that transforms horizontal motion into amplified vertical motion, with accommodation for variable displacement sensitivity. Unlike conventional hanging pendulum thrust stands, the deflection is independent of the length of the pendulum arm, and no reference structure is required at the end of the pendulum. Displacement is measured using a non-contact, optical linear gap displacement transducer. Mechanical oscillations are attenuated using a passive, eddy current damper. An on-board microprocessor-based level control system, which includes a two axis accelerometer and two linear-displacement stepper motors, continuously maintains the level of the balance mechanism - counteracting mechanical %era drift during thruster testing. A thermal control system, which includes heat exchange panels, thermocouples, and a programmable recirculating water chiller, continuously adjusts to varying thermal loads to maintain the balance mechanism temperature, to counteract thermal drifts. An in-situ calibration rig allows for steady state calibration both prior to and during thruster testing. Thrust measurements were carried out on a well-characterized 1 kW Hall thruster; the thrust stand was shown to produce repeatable results consistent with previously published performance data.

Markusic, T. E.↗
NASA NTRS1998

Effects of Heat Treatment on the Magnetic Properties of Polymer-Bound Iron Particle Cores

Spherical iron particles of three different size distributions, 6-10 microns in diameter, 100 mesh and 30-80 mesh, were mixed with 2.0 wt. % of soluble imide and compression molded at 300 C under 131 MPa. Post fabrication heat treatments were performed at 960 C for 6 hours resulting in a significant enhancement of the permeability in low field region for all the specimens except for the one made of 30-80 mesh particles. The rate of core loss of these specimens at a magnetic induction of 5 kG measured up to 1 kHz shows a noticeable increase after heat treatment which, along with the permeability enhancement, can be explained by the coalescence of particles forming a network of conductivity paths in the specimens. The scanning electron micrographs taken for the 6-10 micron particle specimens show no evidence of heat treatment-induced grain growth. The untreated specimens show a very weak f(sup 2) dependence of the core loss which clearly indicates a negligible contribution from the eddy current loss. In particular, an almost perfect linearity was found in the frequency dependence of the core loss of the untreated specimen made of 100 mesh iron particles.

Namkung, M.↗
NASA NTRS1994

Classification of Magneto-Optic Images using Neural Networks

A real time imaging system with a neural network classifier has been incorporated on a Macintosh computer in conjunction with an MOI system. This system images rivets on aircraft aluminium structures using eddy currents and magnetic imaging. Moment invariant functions from the image of a rivet is used to train a multilayer perceptron neural network to classify the rivets as good or bad (rivets with cracks).

Nath, Shridhar↗
NASA NTRS1993

Experimental Robust Control Studies on an Unstable Magnetic Suspension System

This study is an experimental investigation of the robustness of various controllers designed for the Large Angle Magnetic Suspension Test Fixture (LAMSTF). Both analytical and identified nominal models are used for designing controllers along with two different types of uncertainty models. Robustness refers to maintain- ing tracking performance under analytical model errors and dynamically induced eddy currents, while external disturbances are not considered. Results show that incorporating robustness into analytical models gives significantly better results. However, incorporating incorrect uncertainty models may lead to poorer performance than not designing for robustness at all. Designing controllers based on accurate identified models gave the best performance. In fact, incorporating a significant level of robustness into an accurate nominal model resulted in reduced performance. This paper discusses an assortment of experimental results in a consistent manner using robust control theory.

Lim, Kyong B.↗
NASA NTRS1994

A New Electromagnetic Instrument for Thickness Gauging of Conductive Materials

Eddy current techniques are widely used to measure the thickness of electrically conducting materials. The approach, however, requires an extensive set of calibration standards and can be quite time consuming to set up and perform. Recently, an electromagnetic sensor was developed which eliminates the need for impedance measurements. The ability to monitor the magnitude of a voltage output independent of the phase enables the use of extremely simple instrumentation. Using this new sensor a portable hand-held instrument was developed. The device makes single point measurements of the thickness of nonferromagnetic conductive materials. The technique utilized by this instrument requires calibration with two samples of known thicknesses that are representative of the upper and lower thickness values to be measured. The accuracy of the instrument depends upon the calibration range, with a larger range giving a larger error. The measured thicknesses are typically within 2-3% of the calibration range (the difference between the thin and thick sample) of their actual values. In this paper the design, operational and performance characteristics of the instrument along with a detailed description of the thickness gauging algorithm used in the device are presented.

Fulton, J. P.↗
NASA NTRS2004

Applicability of a Crack-Detection System for Use in Rotor Disk Spin Test Experiments Being Evaluated

Engine makers and aviation safety government institutions continue to have a strong interest in monitoring the health of rotating components in aircraft engines to improve safety and to lower maintenance costs. To prevent catastrophic failure (burst) of the engine, they use nondestructive evaluation (NDE) and major overhauls for periodic inspections to discover any cracks that might have formed. The lowest cost fluorescent penetrant inspection NDE technique can fail to disclose cracks that are tightly closed during rest or that are below the surface. The NDE eddy current system is more effective at detecting both crack types, but it requires careful setup and operation and only a small portion of the disk can be practically inspected. So that sensor systems can sustain normal function in a severe environment, health-monitoring systems require the sensor system to transmit a signal if a crack detected in the component is above a predetermined length (but below the length that would lead to failure) and lastly to act neutrally upon the overall performance of the engine system and not interfere with engine maintenance operations. Therefore, more reliable diagnostic tools and high-level techniques for detecting damage and monitoring the health of rotating components are very essential in maintaining engine safety and reliability and in assessing life.

Abdul-Aziz, Ali↗
NASA NTRS2015

Grainex Mar-M 247 Turbine Disk Life Study for NASA's High Temperature High Speed Turbine Seal Test Facility

An experimental and analytical fatigue life study was performed on the Grainex Mar-M 247 disk used in NASA s Turbine Seal Test Facility. To preclude fatigue cracks from growing to critical size in the NASA disk bolt holes due to cyclic loading at severe test conditions, a retirement-for-cause methodology was adopted to detect and monitor cracks within the bolt holes using eddy-current inspection. For the NASA disk material that was tested, the fatigue strain-life to crack initiation at a total strain of 0.5 percent, a minimum to maximum strain ratio of 0, and a bolt hole temperature of 649 C was calculated to be 665 cycles using -99.95 percent prediction intervals. The fatigue crack propagation life was calculated to be 367 cycles after implementing a safety factor of 2 on life. Thus, the NASA disk bolt hole total life or retirement life was determined to be 1032 cycles at a crack depth of 0.501 mm. An initial NASA disk bolt hole inspection at 665 cycles is suggested with 50 cycle inspection intervals thereafter to monitor fatigue crack growth.

Delgado, Irebert R.↗
NASA NTRS2006

Thrust Stand for Electric Propulsion Performance Evaluation

An electric propulsion thrust stand capable of supporting testing of thrusters having a total mass of up to 125 kg and producing thrust levels between 100 microN to 1 N has been developed and tested. The design features a conventional hanging pendulum arm attached to a balance mechanism that converts horizontal deflections produced by the operating thruster into amplified vertical motion of a secondary arm. The level of amplification is changed through adjustment of the location of one of the pivot points linking the system. Response of the system depends on the relative magnitudes of the restoring moments applied by the displaced thruster mass and the twisting torsional pivots connecting the members of the balance mechanism. Displacement is measured using a non-contact, optical linear gap displacement transducer and balance oscillatory motion is attenuated using a passive, eddy-current damper. The thrust stand employs an automated leveling and thermal control system. Pools of liquid gallium are used to deliver power to the thruster without using solid wire connections, which can exert undesirable time-varying forces on the balance. These systems serve to eliminate sources of zero-drift that can occur as the stand thermally or mechanically shifts during the course of an experiment. An in-situ calibration rig allows for steady-state calibration before, during and after thruster operation. Thrust measurements were carried out on a cylindrical Hall thruster that produces mN-level thrust. The measurements were very repeatable, producing results that compare favorably with previously published performance data, but with considerably smaller uncertainty.

Polzin, Kurt A.↗
NASA NTRS1994

Experiments in Contact Control

The implementation, experimentation, and application of contact control schemes for a 7-DOF Robotics Research arm is presented. Three types of control schemes are presented: compliance cntrol, force control, and dual-mode control. This presentation is concluded with the application of the proposed schemes to perform a contact-based eddy-current inspection task.

robotics contact control compliance control force ↗
NASA NTRS2007

Terahertz NDE Application for Corrosion Detection and Evaluation under Shuttle Tiles

Pulsed Terahertz NDE is being examined as a method to inspect for possible corrosion under Space Shuttle Tiles. Other methods such as ultrasonics, infrared, eddy current and microwave technologies have demonstrable shortcomings for tile NDE. This work applies Terahertz NDE, in the frequency range between 50 GHz and 1 THz, for the inspection of manufactured corrosion samples. The samples consist of induced corrosion spots that range in diameter (2.54 to 15.2 mm) and depth (0.036 to 0.787 mm) in an aluminum substrate material covered with tiles. Results of these measurements are presented for known corrosion flaws both covered and uncovered and for blind tests with unknown corrosion flaws covered with attached tiles. The Terahertz NDE system is shown to detect all artificially manufactured corrosion regions under a Shuttle tile with a depth greater than 0.13 mm.

Anastasi, Robert F.↗
NASA NTRS2001

Low loss pole configuration for multi-pole homopolar magnetic bearings

A new pole configuration for multi-pole homopolar bearings proposed in this invention reduces rotational losses caused by eddy-currents generated when non-uniform flux distributions exist along the rotor surfaces. The new homopolar magnetic bearing includes a stator with reduced pole-to-pole and exhibits a much more uniform rotor flux than with large pole-to-pole gaps. A pole feature called a pole-link is incorporated into the low-loss poles to provide a uniform pole-to-pole gap and a controlled path for pole-to-pole flux. In order to implement the low-loss pole configuration of magnetic bearings with small pole-to-pole gaps, a new stator configuration was developed to facilitate installation of coil windings. The stator was divided into sector shaped pieces, as many pieces as there are poles. Each sector-shaped pole-piece can be wound on a standard coil winding machine, and it is practical to wind precision layer wound coils. To achieve maximum actuation efficiency, it is desirable to use all the available space for the coil formed by the natural geometric configuration. Then, the coils can be wound in a tapered shape. After winding, the sectored-pole-pieces are installed into and fastened by bonding or other means, to a ring of material which encloses the sectored-pole-pieces, forming a complete stator.

Blumenstock, Kenneth A.↗
NASA NTRS2004

Insulator coated magnetic nanoparticulate composites with reduced core loss and method of manufacture thereof

A series of bulk-size magnetic/insulating nanostructured composite soft magnetic materials with significantly reduced core loss and its manufacturing technology. This insulator coated magnetic nanostructured composite is comprises a magnetic constituent, which contains one or more magnetic components, and an insulating constituent. The magnetic constituent is nanometer scale particles (1-100 nm) coated by a thin-layered insulating phase (continuous phase). While the intergrain interaction between the immediate neighboring magnetic nanoparticles separated by the insulating phase (or coupled nanoparticles) provide the desired soft magnetic properties, the insulating material provides the much demanded high resistivity which significantly reduces the eddy current loss. The resulting material is a high performance magnetic nanostructured composite with reduced core loss.

Zhang, Yide↗