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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 55 records · Page 3

All sources NASA NTRS DOE OSTI

NASA NTRS1987

Surface flaw reliability analysis of ceramic components with the SCARE finite element postprocessor program

The SCARE (Structural Ceramics Analysis and Reliability Evaluation) computer program on statistical fast fracture reliability analysis with quadratic elements for volume distributed imperfections is enhanced to include the use of linear finite elements and the capability of designing against concurrent surface flaw induced ceramic component failure. The SCARE code is presently coupled as a postprocessor to the MSC/NASTRAN general purpose, finite element analysis program. The improved version now includes the Weibull and Batdorf statistical failure theories for both surface and volume flaw based reliability analysis. The program uses the two-parameter Weibull fracture strength cumulative failure probability distribution model with the principle of independent action for poly-axial stress states, and Batdorf's shear-sensitive as well as shear-insensitive statistical theories. The shear-sensitive surface crack configurations include the Griffith crack and Griffith notch geometries, using the total critical coplanar strain energy release rate criterion to predict mixed-mode fracture. Weibull material parameters based on both surface and volume flaw induced fracture can also be calculated from modulus of rupture bar tests, using the least squares method with known specimen geometry and grouped fracture data. The statistical fast fracture theories for surface flaw induced failure, along with selected input and output formats and options, are summarized. An example problem to demonstrate various features of the program is included.

Gyekenyesi, John P.↗

NASA NTRS1987

Surface flaw reliability analysis of ceramic components with the SCARE finite element postprocessor program

Gyekenyesi, J. P.↗

NASA NTRS1990

Probabilistic simulation for flaw acceptance by dye-penetrant inspection

This paper examines the problems encountered in assessing the reliability of dye-penetrant nondestructive inspection (NDI) techniques in preventing failures due to undetected surface flaws, as well as from flaw acceptance (Fitness-For-Purpose). A Monte Carlo simulation procedure which includes the major variables of the problem is presented as a means of quantifying reliability. Some issues associated with distribution selection are examined. A methodology for selecting the penetrant type and flaw acceptance size for the specific components analyzed using the simulation is proposed. Current methodology limitations are discussed along with possible future effort. Penetrant selection and acceptable sizes of detected flaws are based on a probabilistic assessment of the effect of component and dye-penetrant system variables on structural reliability.

Russell, D. A.↗

NASA NTRS1994

Electromagnetic Flaw Detector Is Easier To Use

Electromagnetic flaw detector based on eddy-current principle. It nondestructively detects cracks, voids, and other flaws introducing electrical discontinuities into specimens of electrically conductive materials. Circuitry associated with this flaw detector simpler than older eddy-current flaw detectors. Unlike older eddy-current nondestructive testers, calibration ordinarily not needed, and readings interpreted with relative ease.

Clendenin, C. Gerald↗

NASA NTRS1994

The probability of flaw detection and the probability of false calls in nondestructive evaluation equipment

The space industry has developed many composite materials that have high durability in proportion to their weights. Many of these materials have a likelihood for flaws that is higher than in traditional metals. There are also coverings (such as paint) that develop flaws that may adversely affect the performance of the system in which they are used. Therefore there is a need to monitor the soundness of composite structures. To meet this monitoring need, many nondestructive evaluation (NDE) systems have been developed. An NDE system is designed to detect material flaws and make flaw measurements without destroying the inspected item. Also, the detection operation is expected to be performed in a rapid manner in a field or production environment. Some of the most recent video-based NDE methodologies are shearography, holography, thermography, and video image correlation.

Temple, Enoch C.↗

NASA NTRS2003

Flaw Detection for Composite Materials Improved by Advanced Thermal Image Reconstruction Techniques

The development of advanced composite materials for use in space and propulsion components has seen considerable growth over the past few years. In addition to improvements that have been made in material properties and processing techniques, similar growth must be seen in the development of methods for the detection of flaws, either generated in service or during manufacturing. Thermal imaging techniques have proven to be successful for the nondestructive evaluation (NDE) of composite materials, but their detection capabilities decrease as flaw depth increases. The purpose of this research is to investigate advanced thermal imaging methods and thermal image processing technologies to increase the maximum depth below surface that a flaw can be detected and improve the contrast between flawed regions and sound regions.

Martin, Richard E.↗

NASA NTRS2013

Unit-Sphere Anisotropic Multiaxial Stochastic-Strength Model Probability Density Distribution for the Orientation of Critical Flaws

Models that predict the failure probability of monolithic glass and ceramic components under multiaxial loading have been developed by authors such as Batdorf, Evans, and Matsuo. These "unit-sphere" failure models assume that the strength-controlling flaws are randomly oriented, noninteracting planar microcracks of specified geometry but of variable size. This report develops a formulation to describe the probability density distribution of the orientation of critical strength-controlling flaws that results from an applied load. This distribution is a function of the multiaxial stress state, the shear sensitivity of the flaws, the Weibull modulus, and the strength anisotropy. Examples are provided showing the predicted response on the unit sphere for various stress states for isotropic and transversely isotropic (anisotropic) materials--including the most probable orientation of critical flaws for offset uniaxial loads with strength anisotropy. The author anticipates that this information could be used to determine anisotropic stiffness degradation or anisotropic damage evolution for individual brittle (or quasi-brittle) composite material constituents within finite element or micromechanics-based software

Nemeth, Noel↗

DOE OSTI2024

Dual X-ray computed tomography-aided classification of melt pool boundaries and flaws in crept additively manufactured parts

In metal additive manufacturing (AM), understanding the process-structure-performance relationships requires a combination of multi-scale characterization techniques that allows for the measurement of the melt pool shape and boundary and classifying various defects and flaws in the AM parts. Such approaches can be destructive, only 2D in nature, or have a small field of view and can be complex to co-register and analyze. Here, in this work, we present a non-destructive 3D inspection technique that employs dual-energy X-ray computed tomography (XCT) along with a model-based iterative reconstruction (MBIR) and a new segmentation algorithm. The proposed approach and algorithm are not only capable of classifying and quantifying flaws such as pores, cracks, and inclusions, but they also allow for the extraction of microstructural features such as melt pool boundaries (MPB) and melt pool regions (MPR), that can help understand process-structure-performance relationships for alloys under study. As an exemplar application, we employed the method for characterization of an additively manufactured aluminum alloy crept under tensile stress at 300 °C for 1064 h. Our results demonstrate high quality segmentation and classification of various flaws and MPB and MPR, for the first time, using 3D X-ray CT inspection. The delineated MPB and MPR in the crept samples reveal the preferential growth paths of cracks that formed during creep deformation. The technique was used for successfully quantifying the characteristics (number of defects, their density, volume fraction, etc.) of the manufacturing-induced pores and creep-induced cracks, which is necessary to better understand the creep failure mechanisms of the material.

36 MATERIALS SCIENCE↗

DOE OSTI2026

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↗

DOE OSTI2025

FLAW STABILITY ANALYSIS OF SURFACE CRACKS IN DOE STANDARD CANISTERS UNDER OPERATION LOADS AND WELDING RESIDUAL STRESSES

There are over 3000 commercial spent nuclear fuel (SNF) storage canisters that are made of stainless steel and planned for multi-purpose functions of SNF handling: interim storage, transportation, and ultimate disposal at a future SNF disposition location. To date, many multi-purpose canisters (MPC) are located in coastal regions for long-term storage. The canisters are fabricated by welding, and post-welding heat treatment is not required for relieving welding residual stresses (WRS). As a result, these canisters may be susceptible to chloride induced stress corrosion cracking (CISCC) due to the chloride-bearing marine salts. The flaw stability analysis of MPC canisters was performed at SRNL (i.e., PVP2016-4935 and PVP2016-63887) for through-wall flaws and for surface flaws respectively, where WRS was considered, and the failure assessment diagram (FAD)-based fracture mechanics method codified by API 579-1/ASME FFS-1-2007 Edition was adopted.

DOE standard canister↗

NASA NTRS1969

Flaw Growth of 6Al-4V Titanium in a Freon TF Environment

The plane strain threshold stress intensity and sustained stress flaw growth rates were experimentally determined for 6AI-4V S.T.A. titanium forging and weldments in environments of Freon TF at room temperature. Sustained load tests of surface flawed specimens were conducted with the experimental approach based on linear elastic fracture mechanics. It was concluded that sustained stress flaw growth rates, in conjunction with threshold stress intensities, can be used in assessing the service life of pressure vessels.

Tiffany, C. F.↗

NASA NTRS1972

The elastic analysis of the part-circular surface flaw problem by the alternating method.

This paper summarizes and evaluates the work done on the elastic analysis of the surface flaw problem by the application of the alternating method. An attempt is made to describe the alternating method and to present the history of its application to the surface flaw problem and to related problems in fracture mechanics. Stress intensity factors obtained by this method are summarized and compared. Results are also compared to those obtained by investigators using other methods of analysis. An evaluation of the use of the alternating method is presented with the purpose of pointing out the advantages and disadvantages in the application of this technique to the surface flaw problem.

Smith, F. W.↗

NASA NTRS1973

Fatigue flaw growth behavior in stiffened and unstiffened panels loaded in biaxial tension

The effect was investigated of biaxial loading on the flaw growth rate of 2219-T87 aluminum alloy that would be typical of Space Shuttle cryogenic tankage design. The stress distribution and stress concentration factors for several integrally stiffened panels under various loading conditions were obtained. The flaw growth behavior of both stiffened and unstiffened panels under biaxial loading conditions was determined. The effect of a complex stress state was studied by introducing flaws in fillet areas of biaxially loaded stiffened panels.

Beck, E. J.↗

NASA NTRS1979

Investigation and characterization of constraint effects on flaw growth during fatigue loading of composite materials

An investigative program is presented in an attempt to add to the current understanding of constraint effects on the response of composite materials under cyclic loading. The objectives were: (1) to use existing data and to develop additional data in order to establish an understanding and quantitative description of flaw growth in unidirectional lamina under cyclic loading at different load direction to fiber direction angles; (2) to establish a similar understanding and description of flaw growth in lamina which are embedded in laminates between other unflawed lamina; (3) to determine the nature of the influence of constraint on flaw growth by quantitatively comparing the results of the tests; and (4) to develop a model and philosophy of constraints effects based on our investigative results.

Stinchcomb, W. W.↗

NASA NTRS1979

Characterization of constraint effects on flaw growth

Experimental results have been presented for the case of a flawed unidirectional lamina constrained by off-axis unflawed plies under static and fatigue loading. Flaw growth in the interior of the laminate, around the embedded flaw, was followed by nondestructive testing methods including video-thermographs and ultrasonic C-scan schemes. Two aspects of the results were distinctive. There was an effort of lamination on damage development which was independent of the presence of the notch, and effects which were directly related to the influence of the notch on the local situation. The results are compared with sectioning studies, surface replication, and stiffness change measurements.

Yeung, P. C.↗

NASA NTRS1981

Battery failure model derived from flaw theory

A previously derived failure model for battery lifetime is discussed in terms of growth rate of the flaw, distribution of flaw sizes, and number of flaws. Equations are presented for determining the failure model for a nickel cadmium battery.

Schulman, I.↗

NASA NTRS1981

Eddy current probe response to open and closed surface flaws

A general analysis of eddy current response to certain types of open and closed surface flaws is presented for both standard low-frequency and ferromagnetic-resonance (FMR) probes. It is shown analytically that for two-dimensional and three-dimensional surface flaws interrogated by a uniform probe field, the crack opening sensitivity increases with the operating frequency of the probe, this behavior being due to the Faraday induction effect. Experiments with low-frequency probes operating at or below 1 MHz and with the FMR probe operating at approximately 1000 MHz confirm this increase of the crack mouth opening displacement for practical situations where the probe field is not uniform in the vicinity of the flaw.

Auld, B. A.↗

NASA NTRS1992

Stress analysis and damage evaluation of flawed composite laminates by hybrid-numerical methods

Structural components in flight vehicles is often inherited flaws, such as microcracks, voids, holes, and delamination. These defects will degrade structures the same as that due to damages in service, such as impact, corrosion, and erosion. It is very important to know how a structural component can be useful and survive after these flaws and damages. To understand the behavior and limitation of these structural components researchers usually do experimental tests or theoretical analyses on structures with simulated flaws. However, neither approach has been completely successful. As Durelli states that 'Seldom does one method give a complete solution, with the most efficiency'. Examples of this principle is seen in photomechanics which additional strain-gage testing can only average stresses at locations of high concentration. On the other hand, theoretical analyses including numerical analyses are implemented with simplified assumptions which may not reflect actual boundary conditions. Hybrid-Numerical methods which combine photomechanics and numerical analysis have been used to correct this inefficiency since 1950's. But its application is limited until 1970's when modern computer codes became available. In recent years, researchers have enhanced the data obtained from photoelasticity, laser speckle, holography and moire' interferometry for input of finite element analysis on metals. Nevertheless, there is only few of literature being done on composite laminates. Therefore, this research is dedicated to this highly anisotropic material.

Yang, Yii-Ching↗