21st Century NDE Revealing Moments … The Stakes Are High Complex parts are difficult to inspect using traditional NDE
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Erin Leigh Lanigan↗
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Why Developing A Full-Sun UV Spectrograph Sounding Rocket Is Difficult but Necessary
For a conference focused on a 20-year perspective of where we have been and where we are going, this talk will highlight specifically why we need a sounding rocket to lead the way in obtaining high-resolution UV spectroscopy of our sun-as-a-star. The currently available data is either sparse or at a much lower resolution when compared with Hubble (HST) spectra of other stars. Because of this, we cannot say with certainty if our Sun’s variability is typical. This limitation is hindering our quest to place our Sun in it’s rightful place on our star-charts. Ultraviolet light is a key component in determining this. Elements such as Hydrogen and Iron have strong emission lines here, and from them we can determine many things about the star from which they originate. The width of these spectral features can tell us about the relative plasma activity on the surface of the star, the abundance of those elements, and of course the temperatures. This has of course been done with many instruments that have very narrow field of views and/or narrow bandwidths. The only way to directly compare our Sun’s UV ”fingerprint” with other stars is to take an image of it in the same manner by which HST does: as a point source object. Our team’s aim has been to develop a sounding rocket capable of doing just that. Along the way, the many challenges we face are producing many solutions. A unique take on the traditional Rowland circle spectrograph will allow us to cover a large range of UV spectra with minimal moving parts. A novel in-situ gain calibration technique will be used in order to maintain the high level of radiometric accuracy desired. Naturally, complications arise when one takes UV measurements as you are flying out of earth’s atmosphere and back into it. Though it may be minor, the absorbed UV spectra from the atmosphere will have to be accounted for. In preparing for this, we have stumbled across a way in which those ”telluric” absorption lines may prove useful for spectral calibration purposes. In addition, raw data from previous sounding rocket missions may have hidden within them useful information for the atmospheric-physics community. In this talk, we will highlight the unique calibration problems and solutions we have faced, and how those are of greater importance to the greater heliophysics and atmospheric communities. With these amazing developments at hand, the future of heliophysics instrumentation is looking bright. This material is based upon work supported by the NSF EPSCoR RII-Track-1.2a (Non-invasive plasma diagnostics for LTP) Cooperative Agreement OIA-1655280. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the authors and do not necessarily reflect the views of the National Science Foundation.
NASA, UAH, MSU, Sounding Rocket, Aeronomy, Instrum↗
Active Pixel Sensors: Are CCD's Dinosaurs?
Charge-coupled devices (CCD's) are presently the technology of choice for most imaging applications. In the 23 years since their invention in 1970, they have evolved to a sophisticated level of performance. However, as with all technologies, we can be certain that they will be supplanted someday. In this paper, the Active Pixel Sensor (APS) technology is explored as a possible successor to the CCD. An active pixel is defined as a detector array technology that has at least one active transistor within the pixel unit cell. The APS eliminates the need for nearly perfect charge transfer -- the Achilles' heel of CCDs. This perfect charge transfer makes CCD's radiation 'soft,' difficult to use under low light conditions, difficult to manufacture in large array sizes, difficult to integrate with on-chip electronics, difficult to use at low temperatures, difficult to use at high frame rates, and difficult to manufacture in non-silicon materials that extend wavelength response.
Fossum, Eric R.↗
An experimental evaluation of error seeding as a program validation technique
A previously reported experiment in error seeding as a program validation technique is summarized. The experiment was designed to test the validity of three assumptions on which the alleged effectiveness of error seeding is based. Errors were seeded into 17 functionally identical but independently programmed Pascal programs in such a way as to produce 408 programs, each with one seeded error. Using mean time to failure as a metric, results indicated that it is possible to generate seeded errors that are arbitrarily but not equally difficult to locate. Examination of indigenous errors demonstrated that these are also arbitrarily difficult to locate. These two results support the assumption that seeded and indigenous errors are approximately equally difficult to locate. However, the assumption that, for each type of error, all errors are equally difficult to locate was not borne out. Finally, since a seeded error occasionally corrected an indigenous error, the assumption that errors do not interfere with each other was proven wrong. Error seeding can be made useful by taking these results into account in modifying the underlying model.
Knight, J. C.↗
Formation and Combustion of Unconfined Drop Clusters in Microgravity
Single-drop and droplet array studies have become common methods to isolate and investigate the effects of any of the complexities that enter into the drop combustion process. Microgravity environments are required to allow larger drops to be studied while minimizing or eliminating the confounding effects of buoyancy. Based on the results from current isolated drop, drop array, and spray studies funded through the Microgravity Science and Applications Division, it has become clear that even with the effects of buoyancy removed, the extrapolation of results from droplet array studies to spray flames is difficult. The problem occurs because even the simplest spray systems introduce complexities of multi-disperse drop sizes and drop-drop interactions, coupled with more complicated fluid dynamics. Not only do these features make the interpretation of experimental data difficult, they also make the problem very difficult to analyze computationally. Group combustion models, in which the interaction between droplets is treated on a statistical manner, have become a popular method to investigate the behavior of large numbers of interacting droplets, particularly through the work of Ryan et al. and Bellan and co-workers. While these models idealize the actual spray systems to a point where they can be treated computationally, the experimental analogy to these models is difficult to achieve because it requires the formation and Combustion of drop clusters without the effects of buoyancy. Therefore, even though these models have provided useful and insightful information, the verification of the results by direct comparison with experimental data is still lacking.
Liu, S.↗
A Design Heritage-Based Forecasting Methodology for Risk Informed Management of Advanced Systems
The development of next generation systems often carries with it the promise of improved performance, greater reliability, and reduced operational costs. These expectations arise from the use of novel designs, new materials, advanced integration and production technologies intended for functionality replacing the previous generation. However, the novelty of these nascent technologies is accompanied by lack of operational experience and, in many cases, no actual testing as well. Therefore some of the enthusiasm surrounding most new technologies may be due to inflated aspirations from lack of knowledge rather than actual future expectations. This paper proposes a design heritage approach for improved reliability forecasting of advanced system components. The basis of the design heritage approach is to relate advanced system components to similar designs currently in operation. The demonstrated performance of these components could then be used to forecast the expected performance and reliability of comparable advanced technology components. In this approach the greater the divergence of the advanced component designs from the current systems the higher the uncertainty that accompanies the associated failure estimates. Designers of advanced systems are faced with many difficult decisions. One of the most common and more difficult types of these decisions are those related to the choice between design alternatives. In the past decision-makers have found these decisions to be extremely difficult to make because they often involve the trade-off between a known performing fielded design and a promising paper design. When it comes to expected reliability performance the paper design always looks better because it is on paper and it addresses all the know failure modes of the fielded design. On the other hand there is a long, and sometimes very difficult road, between the promise of a paper design and its fulfillment; with the possibility that sometimes the reliability promise is not fulfilled at all. Decision makers in advanced technology areas have always known to discount the performance claims of a design to a degree in proportion to its stage of development, and at times have preferred the more mature design over the one of lesser maturity even with the latter promising substantially better performance once fielded. As with the broader measures of performance this has also been true for projected reliability performance. Paper estimates of potential advances in design reliability are to a degree uncertain in proportion to the maturity of the features being proposed to secure those advances. This is especially true when performance-enhancing features in other areas are also planned to be part of the development program.
Maggio, Gaspare↗
Improved Method of Design for Folding Inflatable Shells
An improved method of designing complexly shaped inflatable shells to be assembled from gores was conceived for original application to the inflatable outer shell of a developmental habitable spacecraft module having a cylindrical mid-length section with toroidal end caps. The method is also applicable to inflatable shells of various shapes for terrestrial use. The method addresses problems associated with the assembly, folding, transport, and deployment of inflatable shells that may comprise multiple layers and have complex shapes that can include such doubly curved surfaces as toroids and spheres. One particularly difficult problem is that of mathematically defining fold lines on a gore pattern in a double- curvature region. Moreover, because the fold lines in a double-curvature region tend to be curved, there is a practical problem of how to implement the folds. Another problem is that of modifying the basic gore shapes and sizes for the various layers so that when they are folded as part of the integral structure, they do not mechanically interfere with each other at the fold lines. Heretofore, it has been a common practice to design an inflatable shell to be assembled in the deployed configuration, without regard for the need to fold it into compact form. Typically, the result has been that folding has been a difficult, time-consuming process resulting in a An improved method of designing complexly shaped inflatable shells to be assembled from gores was conceived for original application to the inflatable outer shell of a developmental habitable spacecraft module having a cylindrical mid-length section with toroidal end caps. The method is also applicable to inflatable shells of various shapes for terrestrial use. The method addresses problems associated with the assembly, folding, transport, and deployment of inflatable shells that may comprise multiple layers and have complex shapes that can include such doubly curved surfaces as toroids and spheres. One particularly difficult problem is that of mathematically defining fold lines on a gore pattern in a double- curvature region. Moreover, because the fold lines in a double-curvature region tend to be curved, there is a practical problem of how to implement the folds. Another problem is that of modifying the basic gore shapes and sizes for the various layers so that when they are folded as part of the integral structure, they do not mechanically interfere with each other at the fold lines. Heretofore, it has been a common practice to design an inflatable shell to be assembled in the deployed configuration, without regard for the need to fold it into compact form. Typically, the result has been that folding has been a difficult, time-consuming process resulting in a
Johnson, Christopher J.↗
High Temperature Material Property Data and Challenges to Thermal Process Model Predictions and In-Situ/Ex-Situ Measurements for Metallic Additive Manufacturing
Understanding and predicting performance properties of parts produced by metallic additive manufacturing has improved significantly over the past decade; however, difficult to measure material properties and process outcomes continue to be challenges. The qualification or certification of aerospace parts require extensive measures to quantify variable part properties in order to buy down the risk of component failure. The variability, inherent to the additive manufacturing, process adds unwanted uncertainty in the production of load critical structural components. Process modeling has proven valuable in providing predictions and context for understanding outcomes of the additive manufacturing process; however, these physically informed process models require material properties at temperatures that are difficult to measure and rarely available. Further, calibrating or validating such models is difficult because the process itself is challenging to measure. This talk will explore some of the challenges resulting from difficult to acquire input data by relating thermal process model predictions to in-situ and ex-situ optical microscopy measurements.
Process Model↗
High Fidelity Adaptively Refined CFD and Reduced Order Models of a High Aspect Ratio Aeroelastic Wing Wind Tunnel Model
Robust adaptive mesh refinement for transonic conditions is one of the most difficult challenges to advancing CFD usage for certification by analysis. Transonic fluid-structure interaction cases represent an even more difficult challenge for adaptive mesh refinement. Production aircraft furthermore have structural models that have gaps and discontinuities that make the interdomain transfer of loads and deflections difficult. This adds to the challenge of adaptive mesh refinement. An initial attempt to create an adaptive mesh refinement process that refines regions of high flow gradient based around the HeldenMesh software is presented. The method is applied to the Integrated Adaptive Wing Technology Maturation (IAWTM) configuration. That has developed an aspect ratio 13.5 wing aeroelastic wind-tunnel model for testing in the Transonic Dynamics Tunnel (TDT). The high levels of deformation of this wing make the adaptation of meshes for the static shape difficult and has necessitated some creativity in how to efficiently adapt meshes. A time-domain identification of the unsteady system based on flexible modes using the adapted meshes is performed.
Robert E. Bartels↗
Evaluating the Trustworthiness of Deep Neural Networks in Deployment – A Comparative Study (Replicability Study)
As deep neural networks (DNNs) are increasingly used in safety critical applications, there is a growing concern for their trustworthiness. Even highly trained, high-performant networks are not 100% accurate. However, it is very difficult to predict their behaviour during deployment without ground truth. In this paper, we provide a comparative and replicability study on recent approaches that have been proposed to evaluate the trustworthiness of DNNs. We find that it is very difficult to run and reproduce the results for these approaches on their replication packages, and it is even more difficult to run the tools on artifacts other than their own. Further, it is difficult to compare the effectiveness of the tools, due to lack of clearly defined evaluation metrics. Our results indicate that more effort is needed in our research community to obtain sound techniques for evaluating the trustworthiness of neural networks in safety-critical domains. To this end, we contribute an evaluation framework that incorporates the considered approaches and enables evaluation on common benchmarks, using common metrics. Using this framework, we run a comparative study of the three approaches.
Trustworthy AI↗
Experiments in control of flexible structures with noncolocated sensors and actuators
While the stable control of such flexible structures as limber spacecraft is easily achieved through the colocation of control actuators with sensors, noncolocation renders this extremely difficult. The most difficult case in point is that in which structural damping is low and spacecraft stiffness and inertia values are uncertain and changing. Attention is presently given to an apparatus in which each basic sensor/actuator noncolocation configuration is available, and inertias can be abruptly halved or doubled during control maneuvers. This feature can impose a sudden reversal in the plant's pole-zero sequence, which is a very difficult condition for the controller. Test results obtained to date demonstrate the inherent difficulty of achieving robustness in the case of noncolocation. It is noted that there may be very simple configurations in which there is no alternative to adaptive control.
Cannon, R. H., Jr.↗
The mGA1.0: A common LISP implementation of a messy genetic algorithm
Genetic algorithms (GAs) are finding increased application in difficult search, optimization, and machine learning problems in science and engineering. Increasing demands are being placed on algorithm performance, and the remaining challenges of genetic algorithm theory and practice are becoming increasingly unavoidable. Perhaps the most difficult of these challenges is the so-called linkage problem. Messy GAs were created to overcome the linkage problem of simple genetic algorithms by combining variable-length strings, gene expression, messy operators, and a nonhomogeneous phasing of evolutionary processing. Results on a number of difficult deceptive test functions are encouraging with the mGA always finding global optima in a polynomial number of function evaluations. Theoretical and empirical studies are continuing, and a first version of a messy GA is ready for testing by others. A Common LISP implementation called mGA1.0 is documented and related to the basic principles and operators developed by Goldberg et. al. (1989, 1990). Although the code was prepared with care, it is not a general-purpose code, only a research version. Important data structures and global variations are described. Thereafter brief function descriptions are given, and sample input data are presented together with sample program output. A source listing with comments is also included.
Goldberg, David E.↗
SCATHA mission termination report
The SCATHA (Spacecraft Charging at High Altitudes) satellite was operated from the Consolidated Space Test Center in Sunnyvale, California from February 1979 to May 1991. It was a spin stabilized vehicle in a highly eccentric orbit that collected data on spacecraft charging. The purpose of such data gathering was to predict and/or model the effects of the Earth's magnetic field on synchronous and near synchronous satellites. During the majority of its lifetime, attitude precession maneuvers were done every 10-15 days to maintain solar panel orientation. Maneuver planning was difficult due to the structural characteristics of SCATHA. It is cylindrically shaped and has seven booms ranging in length from 2 to 50 meters. These precession maneuvers induced predictable nutation that damped out after a few days. Eventually fuel began running low due to these frequent maneuvers. Experiments that had required the spin axis be in the orbit plane had already been turned off or had collected all their data. To increase the vehicle lifetime, the spin axis was moved to ecliptic normal. While this stopped the need for frequent attitude maneuvering (only two per year required now), this movement of the spin axis caused nutation that would not damp out for the remainder of the mission. This phase of the mission, with the ecliptic normal orientation, lasted for approximately three years. Although nutation never damped, data gathering was uninterrupted. In late 1990, when SCATHA's transmitter became seriously degraded, the Air Force decided to turn SCATHA off. This would only be done after the satellite was made 'safe'. The most difficult part of making the vehicle safe was quickly purging the fuel. Several plans were considered. The selected plan was to perform a series of 20 degree attitude precession maneuvers (3 days apart to allow for the worst nutation to damp) until the fuel was depleted. Although this sounded simple, the actual execution proved difficult. This was due to a nearly complete lack of available telemetry data, large undamped motion of the long booms, inadequacies in attitude determination software, and an error in the fuel level calculation software. This paper discusses the various proposed termination plans and execution of the selected one. Attitude determination methodologies, nutation from maneuvers, and effects of the flexible booms on the termination mission are presented and analyzed from a satellite analyst point of view.
Stakkestad, Kjell↗
Low bandwidth robust controllers for flight
Through throttle manipulations, engine thrust can be used for emergency flight control for multi-engine aircraft. Previous study by NASA Dryden has shown the use of throttles for emergency flight control to be very difficult. In general, manual fly-by-throttle is extremely difficult - with landing almost impossible, but control augmentation makes runway landings feasible. Flight path control using throttles-only to achieve safe emergency landing for a large jet transport airplane, Boeing 720, was investigated using Quantitative Feedback Theory (QFT). Results were compared to an augmented control developed in a previous simulation study. The control augmentation corrected the unsatisfactory open-loop characteristics by increasing system bandwidth and damping, but increasing the control bandwidth substantially proved very difficult. The augmented pitch control is robust under no or moderate turbulence. The augmented roll control is sensitive to configuration changes.
Biezad, Daniel J.↗
Assessment of impact damage of composite rocket motor cases
This contract reviewed the available literature on mechanisms of low velocity impact damage in filament wound rocket motor cases, MDE methods to quantify damage, critical coupon level test methods, manufacturing and material process variables and empirical and analytical modeling off impact damage. The critical design properties for rocket motor cases are biaxial hoop and axial tensile strength. Low velocity impact damage is insidious because it can create serious nonvisible damage at very low impact velocities. In thick rocket motor cases the prevalent low velocity impact damage is fiber fracture and matrix cracking adjacent to the front face. In contrast, low velocity loading of thin wall cylinders induces flexure, depending on span length and the flexure induces delamination and tensile cracking on the back face wall opposed to impact occurs due to flexural stresses imposed by impact loading. Important NDE methods for rocket motor cases are non-contacting methods that allow inspection from one side. Among these are vibrothermography, and pulse-echo methods based on acoustic-ultrasonic methods. High resolution techniques such as x-ray computed tomography appear to have merit for accurate geometrical characterization of local damage to support development of analytical models of micromechanics. The challenge of coupon level testing is to reproduce the biaxial stress state that the full scale article experiences, and to determine how to scale the composite structure to model full sized behavior. Biaxial tensile testing has been performed by uniaxially tensile loading internally pressurized cylinders. This is experimentally difficult due to gripping problems and pressure containment. Much prior work focused on uniaxial tensile testing of model filament wound cylinders. Interpretation of the results of some studies is complicated by the fact that the fabrication process did not duplicate full scale manufacturing. It is difficult to scale results from testing subscale cylinders since there are significant differences in out time of the resins relative to full scale cylinder fabrication, differences in hoop fiber tensioning and unsatisfactory coupon configurations. It appears that development of a new test method for subscale cylinders is merited. Damage tolerance may be improved by material optimization that uses fiber treatments and matrix modifications to control the fiber matrix interface bonding. It is difficult to develop process optimization in subscale cylinders without also modeling the longer out times resins experience in full scale testing. A major breakthrough in characterizing the effect of impact damage on residual strength, and understanding how to scale results of subscale evaluations, will be a sound micromechanical model that described progressive failure of the composite. Such models will utilize a three dimensional stress analysis due to the complex nature of low velocity impact stresses in thick composites. When these models are coupled with non-contact NDE methods that geometrically characterize the damage and acoustic methods that characterize the effective local elastic properties, accurate assessment of residual strength from impact damage may be possible. Directions for further development are suggested.
Paris, Henry G.↗
Vaccum Gas Tungsten Arc Welding, phase 1
This two year program will investigate Vacuum Gas Tungsten Arc Welding (VGTAW) as a method to modify or improve the weldability of normally difficult-to-weld materials. VGTAW appears to offer a significant improvement in weldability because of the clean environment and lower heat input needed. The overall objective of the program is to develop the VGTAW technology and implement it into a manufacturing environment that will result in lower cost, better quality and higher reliability aerospace components for the space shuttle and other NASA space systems. Phase 1 of this program was aimed at demonstrating the process's ability to weld normally difficult-to-weld materials. Phase 2 will focus on further evaluation, a hardware demonstration and a plan to implement VGTAW technology into a manufacturing environment. During Phase 1, the following tasks were performed: (1) Task 11000 Facility Modification - an existing vacuum chamber was modified and adapted to a GTAW power supply; (2) Task 12000 Materials Selection - four difficult-to-weld materials typically used in the construction of aerospace hardware were chosen for study; (3) Task 13000 VGTAW Experiments - welding experiments were conducted under vacuum using the hollow tungsten electrode and evaluation. As a result of this effort, two materials, NARloy Z and Incoloy 903, were downselected for further characterization in Phase 2; and (4) Task 13100 Aluminum-Lithium Weld Studies - this task was added to the original work statement to investigate the effects of vacuum welding and weld pool vibration on aluminum-lithium alloys.
Weeks, J. L.↗
Adaptive grid methods for RLV environment assessment and nozzle analysis
Rapid access to highly accurate data about complex configurations is needed for multi-disciplinary optimization and design. In order to efficiently meet these requirements a closer coupling between the analysis algorithms and the discretization process is needed. In some cases, such as free surface, temporally varying geometries, and fluid structure interaction, the need is unavoidable. In other cases the need is to rapidly generate and modify high quality grids. Techniques such as unstructured and/or solution-adaptive methods can be used to speed the grid generation process and to automatically cluster mesh points in regions of interest. Global features of the flow can be significantly affected by isolated regions of inadequately resolved flow. These regions may not exhibit high gradients and can be difficult to detect. Thus excessive resolution in certain regions does not necessarily increase the accuracy of the overall solution. Several approaches have been employed for both structured and unstructured grid adaption. The most widely used involve grid point redistribution, local grid point enrichment/derefinement or local modification of the actual flow solver. However, the success of any one of these methods ultimately depends on the feature detection algorithm used to determine solution domain regions which require a fine mesh for their accurate representation. Typically, weight functions are constructed to mimic the local truncation error and may require substantial user input. Most problems of engineering interest involve multi-block grids and widely disparate length scales. Hence, it is desirable that the adaptive grid feature detection algorithm be developed to recognize flow structures of different type as well as differing intensity, and adequately address scaling and normalization across blocks. These weight functions can then be used to construct blending functions for algebraic redistribution, interpolation functions for unstructured grid generation, forcing functions to attract/repel points in an elliptic system, or to trigger local refinement, based upon application of an equidistribution principle. The popularity of solution-adaptive techniques is growing in tandem with unstructured methods. The difficultly of precisely controlling mesh densities and orientations with current unstructured grid generation systems has driven the use of solution-adaptive meshing. Use of derivatives of density or pressure are widely used for construction of such weight functions, and have been proven very successful for inviscid flows with shocks. However, less success has been realized for flowfields with viscous layers, vortices or shocks of disparate strength. It is difficult to maintain the appropriate mesh point spacing in the various regions which require a fine spacing for adequate resolution. Mesh points often migrate from important regions due to refinement of dominant features. An example of this is the well know tendency of adaptive methods to increase the resolution of shocks in the flowfield around airfoils, but in the incorrect location due to inadequate resolution of the stagnation region. This problem has been the motivation for this research.
Thornburg, Hugh J.↗
Low Bandwidth Robust Controllers for Flight
Through throttle manipulations, engine thrust can be used for emergency flight control for multi-engine aircraft. Previous study by NASA Dryden has shown the use of throttles for emergency flight control to be very difficult. In general, manual fly-by-throttle is extremely difficult - with landing almost impossible, but control augmentation makes runway landings feasible. Flight path control using throttles-only to achieve safe emergency landing for a large jet transport airplane, Boeing 720, was investigated using Quantitative Feedback Theory (QFT). Results were compared to an augmented control developed in a previous simulation study. The control augmentation corrected the unsatisfactory open-loop characteristics by increasing system bandwidth and damping, but increasing the control bandwidth substantially proved very difficult. The augmented pitch control is robust under no or moderate turbulence. The augmented roll control is sensitive to configuration changes.
Biezad, Daniel J.↗