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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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Quartz optical fibers improve performance at ultraviolet wavelengths. Borescope used to inspect interior of small-diameter tubing by visible light and ultraviolet light. Employs quartz fibers to conduct ultraviolet light and visible light with high efficiency.
Old techniques refined and combined to make new polarizers. Equipment and procedures developed for fabrication and inspection of large, precisely-spaced, flat grids of wire. Technology includes refinements and combinations of established techniques for winding grids of electron tubes and ruling optical gratings and incorporates recent developments in electronic control and laser/electronic-based metrology. Wire wrapped on frame half translated under automatic control to achieve desired space between turns. Frame halves put together, and excess wire cut away, leaving finished grid mounted in frame. Useful as polarizers and beam splitters for electromagnetic radiation in overlapping ranges of long infrared and microwaves.
Procedure for inspection in spaces above dropped ceilings that contain asbestos saves time and effort without sacrificing safety. With new method, only items of safety equipment needed are glove bag, storage bag, and roll of adhesive tape. Inspector tapes glove bag tightly to support grid around ceiling tile to be removed. With hands in gloves inspector lifts tile gently and places it aside. Extending head and shoulders into bag, inspector examines space above ceiling with help of flashlight.
Surfaces to be bonded tested for cleanliness. Equipment includes commercial photoelectron-emission sensor. Inspected surface irradiated with ultraviolet photons from source in sensor head while anode in sensor head collects photoelectrons ejected from surface by absorbed photons. If intensity and spectrum of ultraviolet light and distance between sensor and surface held constant, then photocurrent varies according to amount and type of contamination.
Molecular contamination of bonding surfaces can drastically affect the bond strength that can be achieved and therefore the structural integrity and reliability of the bonded part. The presence of thin contaminant films on bonding surfaces can result from inadequate or incomplete cleaning methods, from oxide growth during the time between cleaning (such as grit blasting) and bonding, or from failure to properly protect cleaned surfaces from oils, greases, fingerprints, release agents, or deposition of facility airborne molecules generated by adjacent manufacturing or processing operations. Required cleanliness levels for desired bond performance can be determined by testing to correlate bond strength with contaminant type and quantity, thereby establishing the degree of contamination that can be tolerated based on the strength that is needed. Once the maximum acceptable contaminant level is defined, a method is needed to quantitatively measure the contaminant level on the bonding surface prior to bonding to verify that the surface meets the established cleanliness requirement. A photoelectron emission technique for the nondestructive inspection of various bonding surfaces, both metallic and nonmetallic, to provide quantitative data on residual contaminant levels is described. The technique can be used to scan surfaces at speeds of at least 30 ft/min using a servo system to maintain required sensor to surface spacing. The fundamental operation of the photoelectron emission sensor system is explained and the automated scanning system and computer data acquisition hardware and software are described.
The successful development and deployment of reusable tethers for space applications will require methods for detecting, locating, and repairing damage to the tether. This requirement becomes especially important whenever the safety of the STS or the Space Station may be diminished or when critical supplies or systems would be lost in the event of a tether failure. A joint NASA/PSN study endeavor has recently been initiated to evaluate and address the problems to be solved for such an undertaking. The objectives of the Tether Inspection and Repair Experiment (TIRE) are to develop instrumentation and repair technology for specific classes of tethers defined as standards, and to demonstrate the technologies in ground-based and in-flight testing on the STS.
Visual-inspection probe that resembles borescope enables observer at ambient temperature to view objects immersed in turbulent flow of liquid oxygen, liquid nitrogen, or other cryogenic fluid. Design of probe fairly conventional, except special consideration given to selection of materials and to thermal expansion to provide for expected range of operating temperatures. Penetrates wall of cryogenic chamber to provide view of interior. Similar probe illuminates scene. View displayed on video monitor.
New etching solution for chemical penetrant inspection of Inconel(R) 718 castings and weldments. Etchant does not introduce artifacts mistaken for defects. Applied by swabbing or by immersion. Used to detect unwanted residues of Nioro(R) (or equivalent) gold brazing alloy on type 347 stainless steel.
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.
Thermographic nondestructive evaluation techniques were investigated for possible application on Space Shuttle solid rocket booster field joint hardware. This investigation included evaluation of the clevis and tang mating surfaces for scratches and measurement of grease film thickness. The field joint insulation system was inspected for voids and disbonds.
Third-generation profilometer for inspection of butt welds includes hand-held probe unit operating in conjunction with computer. Unit positioned across weld, in contact with workpiece, to obtain profile. Increases precision by reducing subjective inputs and concomitant variations in outputs among different operators. Computerization retains capabilities of first- and second-generation profilometers to measure peak angles and mismatches of butt welds and extends measurement capabilities into field of image analysis. Output data more readily processable into forms used by same or another computer.
Compact, inexpensive tool used in place of expensive borescopes. Shortens inspection/photographing process. Includes two small metal or glass mirrors hinged together. Two 3-V light bulbs attached along edges of one mirror and connected to battery of two cells. Inserted into narrow opening of clevis or tand, and surface viewed and photographed in opposite mirror. Useful in assembly of segments of solid rocket motors as well as in postflight assessment, engineering evaluation, and refurbishment. Also applied in general to inspection and photographing of inner sealing surfaces to which access difficult.
The goal of this project was to develop the system necessary to demonstrate in the laboratory that an eddy current system can inspect the tubes and welds described, screening for the existence of flaws equal in size to, or larger than, the target flaw. The laboratory system was to include the probe necessary to traverse the tubing, the electronics to drive (i.e., electrically excite) the probe and receive and process signals from it, a data display, data recording, and playback devices, and microprocessor software or firmware necessary to operate the system.
The goal of this research is to develop a viable NDE technique for the inspection of orbiter thermal protection system (TPS) tile bonds. Phase 2, discussed here, concentrated on developing an empirical understanding of the bonded and unbonded vibration signatures of acreage tiles. Controlled experiments in the laboratory have provided useful information on the dynamic response of TPS tiles. It has been shown that several signatures are common to all the pedigree tiles. This degree of consistency in the tile-SIP (strain isolation pad) dynamic response proves that an unbond can be detected for a known tile and establish the basis for extending the analysis capability to arbitrary tiles for which there are no historical data. The field tests of the noncontacting laser acoustic sensor system, conducted at the Kennedy Space Center (KSC), investigated the vibrational environment of the Orbiter Processing Facility (OPF) and its effect on the measurement and analysis techniques being developed. The data collected showed that for orbiter locations, such as the body flap and elevon, the data analysis scheme, and/or the sensor, will require modification to accommodate the ambient motion. Several methods were identified for accomplishing this, and a solution is seen as readily achievable. It was established that the tile response was similar to that observed in the laboratory. Of most importance, however, is that the field environment will not affect the physics of the dynamic response that is related to bond condition. All of this information is fundamental to any future design and development of a prototype system.
The following separate topics are addressed: (1) improving a robotic tracking system; and (2) providing insights into orbiter position calibration for radiator inspection. The objective of the tracking system project was to provide the capability to track moving targets more accurately by adjusting parameters in the control system and implementing a predictive algorithm. A computer model was developed to emulate the tracking system. Using this model as a test bed, a self-tuning algorithm was developed to tune the system gains. The model yielded important findings concerning factors that affect the gains. The self-tuning algorithms will provide the concepts to write a program to automatically tune the gains in the real system. The section concerning orbiter position calibration provides a comparison to previous work that had been performed for plant growth. It provided the conceptualized routines required to visually determine the orbiter position and orientation. Furthermore, it identified the types of information which are required to flow between the robot controller and the vision system.
The purpose of this experiment is to familiarize the student with fluorescent penetrant inspection and to relate it to classification of various defects. The penetrant method of nondestructive testing is a method for finding discontinuities open to the surface in solids and essentially nonporous bodies. The method employs a penetrating liquid which is applied over the surface and enters the discontinuity or crack. After the excess of penetrant has been cleaned from the surface, the penetrant which exudes or is drawn back out of the crack indicates the presence and location of a discontinuity. The experimental procedure is described.
Three areas of possible commercialization involving robots at the Kennedy Space Center (KSC) are discussed: a six degree-of-freedom target tracking system for remote umbilical operations; an intelligent torque sensing end effector for operating hand valves in hazardous locations; and an automatic radiator inspection device, a 13 by 65 foot robotic mechanism involving completely redundant motors, drives, and controls. Aspects concerning the first two innovations can be integrated to enable robots or teleoperators to perform tasks involving orientation and panal actuation operations that can be done with existing technology rather than waiting for telerobots to incorporate artificial intelligence (AI) to perform 'smart' autonomous operations. The third robot involves the application of complete control hardware redundancy to enable performance of work over and near expensive Space Shuttle hardware. The consumer marketplace may wish to explore commercialization of similiar component redundancy techniques for applications when a robot would not normally be used because of reliability concerns.
Subtle indications of flaws extracted from ultrasonic waveforms. Ultrasonic-inspection system uses artificial intelligence to help in identification of hidden flaws in electron-beam-welded castings. System involves application of flaw-classification logic to analysis of ultrasonic waveforms.