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All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

Method for Estimating Thread Strength Reduction of Damaged Parent Holes with Inserts

During normal assembly and disassembly of bolted-joint components, thread damage and/or deformation may occur. If threads are overloaded, thread damage/deformation can also be anticipated. Typical inspection techniques (e.g. using GO-NO GO gages) may not provide adequate visibility of the extent of thread damage. More detailed inspection techniques have provided actual pitch-diameter profiles of damaged-hardware holes. A method to predict the reduction in thread shear-out capacity of damaged threaded holes has been developed. This method was based on testing and analytical modeling. Test samples were machined to simulate damaged holes in the hardware of interest. Test samples containing pristine parent-holes were also manufactured from the same bar-stock material to provide baseline results for comparison purposes. After the particular parent-hole thread profile was machined into each sample a helical insert was installed into the threaded hole. These samples were tested in a specially designed fixture to determine the maximum load required to shear out the parent threads. It was determined from the pristine-hole samples that, for the specific material tested, each individual thread could resist an average load of 3980 pounds. The shear-out loads of the holes having modified pitch diameters were compared to the ultimate loads of the specimens with pristine holes. An equivalent number of missing helical coil threads was then determined based on the ratio of shear-out loads for each thread configuration. These data were compared with the results from a finite element model (FEM). The model gave insights into the ability of the thread loads to redistribute for both pristine and simulated damage configurations. In this case, it was determined that the overall potential reduction in thread load-carrying capability in the hardware of interest was equal to having up to three fewer threads in the hole that bolt threads could engage. One- half of this potential reduction was due to local pitch-diameter variations and the other half was due to overall pitch-diameter enlargement beyond Class 2 fit. This result was important in that the thread shear capacity for this particular hardware design was the limiting structural capability. The details of the method development, including the supporting testing, data reduction and analytical model results comparison will be discussed hereafter.

Johnson, David L.↗
NASA NTRS2004

Mitigation of Damage to the International Space Station (ISS) from Water Dumps

The International Space Station (ISS) and Orbiter dump water overboard. This water is from the ISS condensate system, and from the Orbiter s fuel cell (supply side) and wastewater (urine and condensate) systems. Water dumped from either the ISS or Orbiter is a possible source of damage. When water is dumped into a vacuum, some of it flashes into a vapor. The expanding vapor bursts the liquid stream into vapor, and small and large liquid/ice particles. The large liquid/ice particles are approximately 2 mm in diameter and have nominal velocities of approximately 31 Wsec (U.S. Lab) and 50 Wsec (Orbiter). As these liquid/ice particles impact, they can cause mechanical damage due to erosion/pitting of sensitive surfaces, including solar array or radiator surfaces. Solar arrays are of particular concern because of the thin optical coatings on the surface of the cells. The thickness of these coatings is in the range of 1300 to 44000 angstroms. Damage to these coatings can cause degradation of the cells optical characteristics. To mitigate damage from water dumps, the characteristics of the water dumps were studied and an impact code was used to study damage to sensitive surfaces. The results were used to develop the constraints needed to mitigate damage to ISS hardware from Orbiter and U.S. Lab dumps.

Schmidl, William↗
NASA NTRS2006

Detection of Storm Damage Tracks with EOS Data

The damage surveys conducted by the NWS in the aftermath of a reported tornadic event are used to document the location of the tornado ground damage track (pathlength and width) and an estimation of the tornado intensity. This study explores the possibility of using near-real-time medium and high spatial resolution satellite imagery from the NASA Earth Observing System satellites to provide additional information for the surveys. Moderate Resolution Imaging Spectroradiometer (MODIS) and Advanced Spaceborne Thermal Emission and Reflection Radiometer (ASTER) data were used to study the damage tracks from three tornadic storms: the La Plata, Maryland, storm of 28 April 2002 and the Ellsinore and Marquand, Missouri, storms of 24 April 2002. These storms varied in intensity and occurred over regions with significantly different land cover. It was found that, depending on the nature of the land cover, tornado damage tracks from intense storms (F1 or greater) and hail storms may be evident in ASTER, Landsat, and MODIS satellite imagery. In areas where the land cover is dominated by forests, the scar patterns can show up very clearly, while in areas of grassland and regions with few trees, scar patterns are not as obvious or cannot be seen at all in the satellite imagery. The detection of previously unidentified segments of a damage track caused by the 24 April 2002 Marquand, Missouri, tornado demonstrates the utility of satellite imagery for damage surveys. However, the capability to detect tornado tracks in satellite imagery depends on the ability to observe the ground without obstruction from space and appears to be as much dependent on the nature of the underlying surface and land cover as on the severity of the tornadic storm.

Jedlovec, Gary J.↗
NASA NTRS2007

Measurement of Damage Profiles from Solar Wind Implantation

NASA's Genesis Mission launched from Cape Canaveral in August of 2001 with the goal of collecting solar wind in ultra-pure materials. The samples were returned to Earth more than three years later for subsequent analysis. Although the solar wind is comprised primarily of protons, it also contains ionized species representing the entire periodic table. The Genesis mission took advantage of the natural momentum of these ionized species to implant themselves in specialized collectors including single crystal Si and SiC. The collectors trapped the solar wind species of interest and sustained significant damage to the surface crystal structure as a result of the ion bombardment. In this work, spectroscopic ellipsometry has been used to evaluate the extent of this damage in Si and SiC samples. These results and models are compared for artificially implanted samples and pristine non-flight material. In addition, the flown samples had accumulated a thin film of molecular contamination as a result of outgassing in flight, and we demonstrate that this layer can be differentiated from the material damage. In addition to collecting bulk solar wind samples (continuous exposure), the Genesis mission actually returned silicon exposed to four different solar wind regimes: bulk, high speed, low speed, and coronal mass ejections. Each of these solar wind regimes varies in energy, but may vary in composition as well. While determining the composition is a primary goal of the mission, we are also interested in the variation in depth and extent of the damage layer as a function of solar wind regime. Here, we examine flight Si from the bulk solar wind regime and compare the results to both pristine and artificially implanted Si. Finally, there were four samples which were mounted in an electrostatic "concentrator" designed to reject a large fraction (>85%) of incoming protons while enhancing the concentration of ions mass 4-28 amu by a factor of at least 20. Two of these samples were single crystal 6H silicon carbide. (The others were polycrystalline CVD diamond and amorphous carbon that were not examined in the work.) The ion damaged SiC samples from the concentrator were studied in comparison to the flight Si from the bulk array to understand differences in the extent of the damage.

McNamara, K. M.↗
NASA NTRS2008

Damage Diagnosis in Semiconductive Materials Using Electrical Impedance Measurements

Recent aerospace industry trends have resulted in an increased demand for real-time, effective techniques for in-flight structural health monitoring. A promising technique for damage diagnosis uses electrical impedance measurements of semiconductive materials. By applying a small electrical current into a material specimen and measuring the corresponding voltages at various locations on the specimen, changes in the electrical characteristics due to the presence of damage can be assessed. An artificial neural network uses these changes in electrical properties to provide an inverse solution that estimates the location and magnitude of the damage. The advantage of the electrical impedance method over other damage diagnosis techniques is that it uses the material as the sensor. Simple voltage measurements can be used instead of discrete sensors, resulting in a reduction in weight and system complexity. This research effort extends previous work by employing finite element method models to improve accuracy of complex models with anisotropic conductivities and by enhancing the computational efficiency of the inverse techniques. The paper demonstrates a proof of concept of a damage diagnosis approach using electrical impedance methods and a neural network as an effective tool for in-flight diagnosis of structural damage to aircraft components.

Ross, Richard W.↗
NASA NTRS2008

Triboluminescent Materials for Smart Optical Damage Sensors for Space Applications

There is a need to develop a new technique of damage detection for composites, which could detect cracking or delamination from any desired location within a material structure in real time. Recently, triboluminescent materials have been proposed as smart sensors of structural damage. To sense the damage, these materials can be epoxy bonded, coated in a polymer matrix, or embedded in a composite host structure. When the damage or fracture takes place in the host structure, the resultant fracture of triboluminescent crystals creates a light emission. This will warn in real time that structural damage has occurred. The triboluminescent emission of the candidate phosphor has to be bright enough that the light reaching from the point of fracture to the detector through a fiber optic cable is detectable. There are a large number of triboluminescent materials, but few satisfy the above criterion. The authors have synthesized an organic material known as Europium tetrakis (dibenzoylmethide) triethylammonium (EuD4TEA), which is a potential candidate for application as a damage sensor and could be made into a wireless sensor with the addition of microchip, antenna, and electronics. Preliminary results on the synthesis and characterization of this material are presented.

Aggarwal, M. D.↗
NASA NTRS2011

Cancer Risk Estimates from Space Flight Estimated Using Yields of Chromosome Damage in Astronaut's Blood Lymphocytes

To date, cytogenetic damage has been assessed in blood lymphocytes from more than 30 astronauts before and after they participated in long-duration space missions of three months or more on board the International Space Station. Chromosome damage was assessed using fluorescence in situ hybridization whole chromosome analysis techniques. For all individuals, the frequency of chromosome damage measured within a month of return from space was higher than their preflight yield, and biodosimetry estimates were within the range expected from physical dosimetry. Follow up analyses have been performed on most of the astronauts at intervals ranging from around 6 months to many years after flight, and the cytogenetic effects of repeat long-duration missions have so far been assessed in four individuals. Chromosomal aberrations in peripheral blood lymphocytes have been validated as biomarkers of cancer risk and cytogenetic damage can therefore be used to characterize excess health risk incurred by individual crewmembers after their respective missions. Traditional risk assessment models are based on epidemiological data obtained on Earth in cohorts exposed predominantly to acute doses of gamma-rays, and the extrapolation to the space environment is highly problematic, involving very large uncertainties. Cytogenetic damage could play a key role in reducing uncertainty in risk estimation because it is incurred directly in the space environment, using specimens from the astronauts themselves. Relative cancer risks were estimated from the biodosimetry data using the quantitative approach derived from the European Study Group on Cytogenetic Biomarkers and Health database. Astronauts were categorized into low, medium, or high tertiles according to their yield of chromosome damage. Age adjusted tertile rankings were used to estimate cancer risk and results were compared with values obtained using traditional modeling approaches. Individual tertile rankings increased after space flight and analysis of follow up samples indicated that the tertile rankings remained in the high category for more than 50% of the individuals assessed so far. Crewmembers that shift and remain in the high category are projected to have increased life-time cancer risk.

George, Kerry A.↗
NASA NTRS2011

DNA Damage Signals and Space Radiation Risk

Space radiation is comprised of high-energy and charge (HZE) nuclei and protons. The initial DNA damage from HZE nuclei is qualitatively different from X-rays or gamma rays due to the clustering of damage sites which increases their complexity. Clustering of DNA damage occurs on several scales. First there is clustering of single strand breaks (SSB), double strand breaks (DSB), and base damage within a few to several hundred base pairs (bp). A second form of damage clustering occurs on the scale of a few kbp where several DSB?s may be induced by single HZE nuclei. These forms of damage clusters do not occur at low to moderate doses of X-rays or gamma rays thus presenting new challenges to DNA repair systems. We review current knowledge of differences that occur in DNA repair pathways for different types of radiation and possible relationships to mutations, chromosomal aberrations and cancer risks.

Cucinotta, Francis A.↗
NASA NTRS2012

Some Examples of the Relations Between Processing and Damage Tolerance

Most structures made of laminated polymer matrix composites (PMCs) must be designed to some damage tolerance requirement that includes foreign object impact damage. Thus from the beginning of a part s life, impact damage is assumed to exist in the material and the part is designed to carry the required load with the prescribed impact damage present. By doing this, some processing defects may automatically be accounted for in the reduced design allowable due to these impacts. This paper will present examples of how a given level of impact damage and certain processing defects affect the compression strength of a laminate that contains both. Knowledge of the impact damage tolerance requirements, before processing begins, can broaden material options and processing techniques since the structure is not being designed to pristine properties.

Nettles, Alan T.↗
NASA NTRS2013

Investigation of Sideband Index Response to Prototype Gear Tooth Damage

The objective of this analysis was to evaluate the ability of gear condition indicators (CI) to detect contact fatigue damage on spiral bevel gear teeth. Tests were performed in the NASA Glenn Spiral Bevel Gear Fatigue Rig on eight prototype gear sets (pinion/gear). Damage was initiated and progressed on the gear and pinion teeth. Vibration data was measured during damage progression at varying torque values while varying damage modes to the gear teeth were observed and documented with inspection photos. Sideband indexes (SI) and root mean square (RMS) CIs were calculated from the time synchronous averaged vibration data. Results found that both CIs respond differently to varying torque levels, damage levels and damage modes

health monitoring↗
NASA NTRS2014

Instantaneous Wavenumber Estimation for Damage Quantification in Layered Plate Structures

This paper illustrates the application of instantaneous and local wavenumber damage quantification techniques for high frequency guided wave interrogation. The proposed methodologies can be considered as first steps towards a hybrid structural health monitoring/ nondestructive evaluation (SHM/NDE) approach for damage assessment in composites. The challenges and opportunities related to the considered type of interrogation and signal processing are explored through the analysis of numerical data obtained via EFIT simulations of damage in CRFP plates. Realistic damage configurations are modeled from x-ray CT scan data of plates subjected to actual impacts, in order to accurately predict wave-damage interactions in terms of scattering and mode conversions. Simulation data is utilized to enhance the information provided by instantaneous and local wavenumbers and mitigate the complexity related to the multi-modal content of the plate response. Signal processing strategies considered for this purpose include modal decoupling through filtering in the frequency/wavenumber domain, the combination of displacement components, and the exploitation of polarization information for the various modes as evaluated through the dispersion analysis of the considered laminate lay-up sequence. The results presented assess the effectiveness of the proposed wavefield processing techniques as a hybrid SHM/NDE technique for damage detection and quantification in composite, plate-like structures.

Mesnil, Olivier↗
NASA NTRS2014

A Numerical and Experimental Study of Damage Growth in a Composite Laminate

The present study has three goals: (1) perform an experiment where a simple laminate damage process can be characterized in high detail; (2) evaluate the performance of existing commercially available laminate damage simulation tools by modeling the experiment; (3) observe and understand the underlying physics of damage in a composite honeycomb sandwich structure subjected to low-velocity impact. A quasi-static indentation experiment has been devised to provide detailed information about a simple mixed-mode damage growth process. The test specimens consist of an aluminum honeycomb core with a cross-ply laminate facesheet supported on a stiff uniform surface. When the sample is subjected to an indentation load, the honeycomb core provides support to the facesheet resulting in a gradual and stable damage growth process in the skin. This enables real time observation as a matrix crack forms, propagates through a ply, and then causes a delamination. Finite element analyses were conducted in ABAQUS/Explicit(TradeMark) 6.13 that used continuum and cohesive modeling techniques to simulate facesheet damage and a geometric and material nonlinear model to simulate core crushing. The high fidelity of the experimental data allows a detailed investigation and discussion of the accuracy of each numerical modeling approach.

McElroy, Mark↗
NASA NTRS2016

Probabilistic Damage Characterization Using the Computationally-Efficient Bayesian Approach

This work presents a computationally-ecient approach for damage determination that quanti es uncertainty in the provided diagnosis. Given strain sensor data that are polluted with measurement errors, Bayesian inference is used to estimate the location, size, and orientation of damage. This approach uses Bayes' Theorem to combine any prior knowledge an analyst may have about the nature of the damage with information provided implicitly by the strain sensor data to form a posterior probability distribution over possible damage states. The unknown damage parameters are then estimated based on samples drawn numerically from this distribution using a Markov Chain Monte Carlo (MCMC) sampling algorithm. Several modi cations are made to the traditional Bayesian inference approach to provide signi cant computational speedup. First, an ecient surrogate model is constructed using sparse grid interpolation to replace a costly nite element model that must otherwise be evaluated for each sample drawn with MCMC. Next, the standard Bayesian posterior distribution is modi ed using a weighted likelihood formulation, which is shown to improve the convergence of the sampling process. Finally, a robust MCMC algorithm, Delayed Rejection Adaptive Metropolis (DRAM), is adopted to sample the probability distribution more eciently. Numerical examples demonstrate that the proposed framework e ectively provides damage estimates with uncertainty quanti cation and can yield orders of magnitude speedup over standard Bayesian approaches.

Warner, James E.↗
NASA NTRS2016

Strain-Based Damage Determination Using Finite Element Analysis for Structural Health Management

A damage determination method is presented that relies on in-service strain sensor measurements. The method employs a gradient-based optimization procedure combined with the finite element method for solution to the forward problem. It is demonstrated that strains, measured at a limited number of sensors, can be used to accurately determine the location, size, and orientation of damage. Numerical examples are presented to demonstrate the general procedure. This work is motivated by the need to provide structural health management systems with a real-time damage characterization. The damage cases investigated herein are characteristic of point-source damage, which can attain critical size during flight. The procedure described can be used to provide prognosis tools with the current damage configuration.

Hochhalter, Jacob D.↗
NASA NTRS2016

Applications of Earth Remote Sensing for Identifying Tornado and Severe Weather Damage

NASA SPoRT (Short-term Prediction Research and Transition Center) provided MODIS (Moderate Resolution Imaging Spectrometer) and ASTER (Advanced Spaceborne Thermal Emission and Reflection Radiometer) imagery to WFOs (Weather Forecast Offices) in Alabama to support April 27th, 2011 damage assessments across the state. SPoRT was awarded a NASA Applied Science: Disasters Feasibility award to investigate the applicability of including remote sensing imagery and derived products into the NOAA/NWS (National Oceanic and Atmospheric Administration/National Weather System) Damage Assessment Toolkit (DAT). Proposal team was awarded the 3-year proposal to implement a web mapping service and associate data feeds from the USGS (U.S. Geological Survey) to provide satellite imagery and derived products directly to the NWS thru the DAT. In the United States, NOAA/NWS is charged with performing damage assessments when storm or tornado damage is suspected after a severe weather event. This has led to the development of the Damage Assessment Toolkit (DAT), an application for smartphones, tablets and web browsers that allows for the collection, geo-location, and aggregation of various damage indicators collected during storm surveys.

Satellite Remote Sensing↗
NASA NTRS2017

Damage Detection Sensor System for Aerospace and Multiple Applications

The damage detection sensory system is an intelligent damage detection ‘skin’ that can be embedded into rigid or flexible structures, providing a lightweight capability for in-situ health monitoring for applications such as spacecraft, expandable or inflatable structures, extravehicular activities (EVA) suits, smart wearables, and other applications where diagnostic impact damage monitoring might be critical. The sensor systems can be customized for detecting location, damage size, and depth, with velocity options and can be designed for particular environments for monitoring of impact or physical damage to a structure. The operation of the sensor detection system is currently based on the use of parallel conductive traces placed on a firm or flexible surface. Several detection layers can be implemented, where alternate layers are arranged in orthogonal direction with respect to the adjacent layers allowing for location and depth calculations. Increased flexibility of the damage detection sensor system designs will also be introduced.

Williams, M.↗
NASA NTRS2018

Plasticity and Damage Modeling of Stress Asymmetry and Dynamic Behavior of AFS Additive Manufactured Aluminum Alloy 2219

The Solid State Additive Manufacturing (AM) process referred as MELD that fabricated the samples in this study, provides a new path for repairing, coating, joining and additive manufacturing metals and metal matrix composites. This research will be the first application of a physics-based microstructure dependent internal state variable (ISV) plasticity and damage material model to capture the mechanical response of an AM Aluminum Alloy (AA) 2219 via the MELD process. In this research, a microstructure-based internal state variable (ISV) plasticity-damage model was used to capture the mechanical behavior of AFS 2219 aluminum alloy. Aeroprobe Corporation, creator and patent holder for the MELD process, fabricated the material by pushing a solid filler rod of AA2219-T861 material through a hollow rotating tool onto an AA2219 T851 plate substrate. As feedstock, solid or powder precursor metals are pushed through a nonconsumable rotating cylindrical tool. Herein, added layers are deposited and metallurgically bonded to substrate material or previously deposited layers by the heat generated from the rotating tool through plastic deformation of the filler material. Once a layer has been added, the tool height increases, and starts the deposition of the next layer. This process results in beneficial properties such as grain refinement, homogenization and reduced porosity (fully dense). This process will experience temperatures similar to those in the weld nugget zone (WNZ) in friction stir welding (FSW), ranging from 0.6-0.9 Tm, with Tm being the melting point of the material. MELD is highly scalable with AA deposition rates reaching over 1000 cm3/hr, which allows for MELD being used for repairs, coatings, and building components. A motivating factor driving the research for physics-based history dependent material modeling of MELD components is the ability to accurately capture the stress-state and strain rate dependence in the material caused by variations in material microstructure from the MELD processing of new or repaired components. The ISV model incorporates microstructural content and is consistent with continuum level kinematics, kinetics, and thermodynamics. These features allow the ISV model to capture large deformations at the structural scale using the kinematic and isotropic hardening, while microscale damage is obtained from the microstructural features. The benefits of the ISV model arise from the inclusion of structure-property relationships identified from microstructural characterization and experimentation. The Bauschinger effect (BE) is an important concept, vital in the accurate prediction of cyclic stress-strain response of ductile materials such as metals. The ISV model has been successfully used to capture the behavior and damage, and the BE of different aluminum alloys and steels. The ISV model uses kinematic and isotropic hardening to help capture deformations of the material at the macro scale. To understand this hardening relationship, calculating the kinematic and isotropic hardening relationship in the material is warranted for a high-fidelity model. Electron Backscattered Diffraction (EBSD) was used to characterize the as-fabricated microstructure, where a fully-dense equiaxed grain morphology with average grain size of 2.5 μm was observed. Microhardness mapping of the as-built structures, monotonic tension and compression experiments at both quasi-static (0.001/s) strain rates, tension-followed-by-compression and compression-followed-by-tension experiments were performed to obtain the set of plasticity and damage constants necessary to capture strain rate and stress state behavior of this additive material. To calibrate the plasticity-damage model, a single set of constants were determined to capture the different stress states the MELD AA2219. One set of the constants was determined from experimental true stress-strain curves for the tension and compression data. Additionally, microstructural information and data from the open literature were used as the other model constants. This research is a first of its kind for AFS AA2219, includes correlating the ISV model to the monotonic experimental results that capture the isotropic and kinematic plasticity mechanical response.

Rivera, O. G.↗
NASA NTRS2018

Real Time Detection of Damage During Quasi-Static Loading of a Single Stringer Panel Using Passive Thermography

Real time nondestructive evaluation is required for composites load testing. 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 can result in the formation of delamination damage between the stiffener flange and skin. Passive thermography was used to detect damage in real time as a function of the applied load. The loading was stopped when damage growth was detected. Of particular interest was the early detection of damage formation which can be challenging, as compared to cyclic fatigue loading. Passive thermography data were acquired and processed in real time and revealed damaged areas due to heating from fiber breakage and delamination formation. The processed thermal imagery was also compared to acoustic emission and ultrasound data.

Zalameda, Joseph N.↗