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At least 73 records · Page 4

All sources NASA NTRS DOE OSTI

NASA NTRS2005

The Application of Infrared Thermographic Inspection Techniques to the Space Shuttle Thermal Protection System

The Nondestructive Evaluation Sciences Branch at NASA s Langley Research Center has been actively involved in the development of thermographic inspection techniques for more than 15 years. Since the Space Shuttle Columbia accident, NASA has focused on the improvement of advanced NDE techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter s wing leading edge. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can be used to inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Principal Component Analysis (PCA) has been shown effective for reducing thermographic NDE data. A typical implementation of PCA is when the eigenvectors are generated from the data set being analyzed. Although it is a powerful tool for enhancing the visibility of defects in thermal data, PCA can be computationally intense and time consuming when applied to the large data sets typical in thermography. Additionally, PCA can experience problems when very large defects are present (defects that dominate the field-of-view), since the calculation of the eigenvectors is now governed by the presence of the defect, not the "good" material. To increase the processing speed and to minimize the negative effects of large defects, an alternative method of PCA is being pursued where a fixed set of eigenvectors, generated from an analytic model of the thermal response of the material under examination, is used to process the thermal data from the RCC materials. Details of a one-dimensional analytic model and a two-dimensional finite-element model will be presented. An overview of the PCA process as well as a quantitative signal-to-noise comparison of the results of performing both embodiments of PCA on thermographic data from various RCC specimens will be shown. Finally, a number of different applications of this technology to various RCC components will be presented.

Cramer, K. E.↗

NASA NTRS2006

Laser Shearography Inspection of TPS (Thermal Protection System) Cork on RSRM (Reusable Solid Rocket Motors)

Laser Shearography is a viable inspection method for detection of de-bonds and voids within the external TPS (thermal protection system) on to the Space Shuttle RSRM (reusable solid rocket motors). Cork samples with thicknesses up to 1 inch were tested at the LTI (Laser Technology Incorporated) laboratory using vacuum-applied stress in a vacuum chamber. The testing proved that the technology could detect cork to steel un-bonds using vacuum stress techniques in the laboratory environment. The next logical step was to inspect the TPS on a RSRM. Although detailed post flight inspection has confirmed that ATK Thiokol's cork bonding technique provides a reliable cork to case bond, due to the Space Shuttle Columbia incident there is a great interest in verifying bond-lines on the external TPS. This interest provided and opportunity to inspect a RSRM motor with Laser Shearography. This paper will describe the laboratory testing and RSRM testing that has been performed to date. Descriptions of the test equipment setup and techniques for data collection and detailed results will be given. The data from the test show that Laser Shearography is an effective technology and readily adaptable to inspect a RSRM.

Lingbloom, Mike↗

NASA NTRS2007

Results of On-Orbit Testing of an Extra-Vehicular Infrared Camera Inspection System

This paper will discuss an infrared camera inspection system that has been developed to allow astronauts to demonstrate the ability to inspect reinforced carbon-carbon (RCC) components on the space shuttle as part of extra-vehicular activities (EVA) while in orbit. Presented will be the performance of the EVA camera system coupled with solar heating for inspection of damaged RCC specimens and NDE standards. The data presented was acquired during space shuttle flights STS-121 and STS-115 as well during a staged EVA from the ISS. The EVA camera system was able to detect flatbottom holes as small as 2.54cm in diameter with 25% material loss. Results obtained are shown to be comparable to ground-based thermal inspections performed in the laboratory using the same camera and simulated solar heating. Data on both the time history of the specimen temperature and the ability of the inspection system to image defects due to impact will likewise be presented.

Howell, Patricia A.↗

NASA NTRS2010

X-Ray Computed Tomography Inspection of the Stardust Heat Shield

The "Stardust" heat shield, composed of a PICA (Phenolic Impregnated Carbon Ablator) Thermal Protection System (TPS), bonded to a composite aeroshell, contains important features which chronicle its time in space as well as re-entry. To guide the further study of the Stardust heat shield, NASA reviewed a number of techniques for inspection of the article. The goals of the inspection were: 1) to establish the material characteristics of the shield and shield components, 2) record the dimensions of shield components and assembly as compared with the pre-flight condition, 3) provide flight infonnation for validation and verification of the FIAT ablation code and PICA material property model and 4) through the evaluation of the shield material provide input to future missions which employ similar materials. Industrial X-Ray Computed Tomography (CT) is a 3D inspection technology which can provide infonnation on material integrity, material properties (density) and dimensional measurements of the heat shield components. Computed tomographic volumetric inspections can generate a dimensionally correct, quantitatively accurate volume of the shield assembly. Because of the capabilities offered by X-ray CT, NASA chose to use this method to evaluate the Stardust heat shield. Personnel at NASA Johnson Space Center (JSC) and Lawrence Livermore National Labs (LLNL) recently performed a full scan of the Stardust heat shield using a newly installed X-ray CT system at JSC. This paper briefly discusses the technology used and then presents the following results: 1. CT scans derived dimensions and their comparisons with as-built dimensions anchored with data obtained from samples cut from the heat shield; 2. Measured density variation, char layer thickness, recession and bond line (the adhesive layer between the PICA and the aeroshell) integrity; 3. FIAT predicted recession, density and char layer profiles as well as bondline temperatures Finally suggestions are made as to future uses of this technology as a tool for non-destructively inspecting and verifying both pre and post flight heat shields.

McNamara, Karen M.↗

NASA NTRS2012

Elements of Nondestructive Examination for the Visual Inspection of Composite Structures

Visual inspection (VI) of composite structures provides an effective, wide field survey to ensure design and material compliance is maintained for the entire service life of the manufactured component. Visual inspection is one of the most commonly used nondestructive inspection methods to assess surface defects on composites. By applying visual inspection elements, mechanical damage that could affect component residual strength can be identified and a disposition reached before a potentially catastrophic event occurs. This technique is non-contact and applied at all stages of the composite structure s processing and use. Additionally, VI is required to be performed in all service environments until decommission. By following Level I and Level II damage accept/reject criteria set forth in this document, the material review (MR) process can be initiated. This nondestructive evaluation (NDE) method should be complemented with additional NDE methods to best understand the nature of the observed indications. When VI identification is followed by interrogation using effective complimentary NDE methods, the final Material Review Board (MRB) disposition of the component can be effectively achieved. Although elements of the visual inspection method are discussed and expressly required by the various range standards (KNPR 8715.3 and AFSPCMAN 91-710), emphasis should be placed on supporting the interpretation of recorded visual observations. Sound engineering practices and procedures should be applied with the interpretation of nondestructive testing (NDT) results when the residual strength data specific to a vessel design is incomplete or absent.

Tommy B. Yoder↗

NASA NTRS2015

Test and Inspection Requirements for Frangible Joints Used in Human-Rated Spacecraft Applications

The purpose of this document is to define a series of test and inspection requirements for a specific type of frangible joint assembly used in human-rated spacecraft applications. It is intended to be an enhancement to the Commercial Crew Program JSC 62809D Human Rated Spacecraft Pyrotechnic Specification and lists very specific tests and inspections with accompanying tables. This document does not eliminate any of the requirements stated in JSC 62809D. Many of the test and inspections in this document are standard operating procedure for pyrotechnics suppliers. This document provides detail on the individual items to avoid ambiguity. In particular, this document details the test and inspection requirements for offset notch style frangible joints with aluminum machined plates. It is expected that a user would tailor the contents of this document for their particular vehicle application and provide a certifying organization with rationale for such tailoring. Tailoring to the requirements of this document requires approval of the certifying organization (e.g. NASA for a NASA human spaceflight program). The FJ must perform in accordance with design specifications after subjection to all environments it would encounter in its lifecycle. This document does not cover all possible environments that may exist in unique applications and a user may determine that additional tests are necessary. The user must develop written inspection and test procedures with detailed acceptance criteria.

Sirri Oguz↗

NASA NTRS2015

Additive Manufacturing Infrared Inspection

The Additive Manufacturing Infrared Inspection Task started the development of a real-time dimensional inspection technique and digital quality record for the additive manufacturing process using infrared camera imaging and processing techniques. This project will benefit additive manufacturing by providing real-time inspection of internal geometry that is not currently possible and reduce the time and cost of additive manufactured parts with automated real-time dimensional inspections which deletes post-production inspections.

Gaddy, Darrell↗

NASA NTRS2016

Post-Test Inspection of NASA's Evolutionary Xenon Thruster Long-Duration Test Hardware: Discharge Chamber

The NEXT Long-Duration Test is part of a comprehensive thruster service life assessment intended to demonstrate overall throughput capability, validate service life models, quantify wear rates as a function of time and operating condition, and identify any unknown life-limiting mechanisms. The test was voluntarily terminated in February 2014 after demonstrating 51,184 hours of high-voltage operation, 918 kg of propellant throughput, and 35.5 MN-s of total impulse. The post-test inspection of the thruster hardware began shortly afterwards with a combination of non-destructive and destructive analysis techniques, and is presently nearing completion. This paper presents relevant results of the post-test inspection for the discharge chamber as well as other miscellaneous components such as the high-voltage propellant isolators and electrical cabling. Comparison of magnetic field measurements taken during pretest and post-test inspections indicate that the field strength did not degrade, consistent with performance data obtained during the test. Inspection of discharge chamber mesh samples show a deposition coating primarily composed of grid material that is approximately 15 micrometers in thickness. This thickness is well within the retention capability of the mesh and is therefore not expected to present any issues. Approximately 3.1 grams of deposition flakes were found at the bottom of the discharge chamber, composed primarily of grid material and carbon. Calculated size histograms of these flakes indicate that 99% have a maximum dimension of 200 micrometers or smaller, which is significantly less than the ion optics grid gap. Larger flakes that are capable of causing a grid-to-grid short will be analyzed to determine if their formation will occur in flight or is a facility effect. The high-voltage propellant isolators as well as numerous other electrical insulators were inspected and no evidence of arcing or any other issues were found.

Electric Propulsion↗

NASA NTRS2017

UAV Inspection of Electrical Transmission Infrastructure with Path Conformance Autonomy and Lidar-Based Geofences NASA Report on UTM Reference Mission Flights at Southern Company Flights November 2016

Flights at low altitudes in close proximity to electrical transmission infrastructure present serious navigational challenges: GPS and radio communication quality is variable and yet tight position control is needed to measure defects while avoiding collisions with ground structures. To advance unmanned aerial vehicle (UAV) navigation technology while accomplishing a task with economic and societal benefit, a high voltage electrical infrastructure inspection reference mission was designed. An integrated air-ground platform was developed for this mission and tested in two days of experimental flights to determine whether navigational augmentation was needed to successfully conduct a controlled inspection experiment. The airborne component of the platform was a multirotor UAV built from commercial off-the-shelf hardware and software, and the ground component was a commercial laptop running open source software. A compact ultraviolet sensor mounted on the UAV can locate 'hot spots' (potential failure points in the electric grid), so long as the UAV flight path adequately samples the airspace near the power grid structures. To improve navigation, the platform was supplemented with two navigation technologies: lidar-to-polyhedron preflight processing for obstacle demarcation and inspection distance planning, and trajectory management software to enforce inspection standoff distance. Both navigation technologies were essential to obtaining useful results from the hot spot sensor in this obstacle-rich, low-altitude airspace. Because the electrical grid extends into crowded airspaces, the UAV position was tracked with NASA unmanned aerial system traffic management (UTM) technology. The following results were obtained: (1) Inspection of high-voltage electrical transmission infrastructure to locate 'hot spots' of ultraviolet emission requires navigation methods that are not broadly available and are not needed at higher altitude flights above ground structures. (2) The sensing capability of a novel airborne UV detector was verified with a standard ground-based instrument. Flights with this sensor showed that UAV measurement operations and recording methods are viable. With improved sensor range, UAVs equipped with compact UV sensors could serve as the detection elements in a self-diagnosing power grid. (3) Simplification of rich lidar maps to polyhedral obstacle maps reduces data volume by orders of magnitude, so that computation with the resultant maps in real time is possible. This enables real-time obstacle avoidance autonomy. Stable navigation may be feasible in the GPS-deprived environment near transmission lines by a UAV that senses ground structures and compares them to these simplified maps. (4) A new, formally verified path conformance software system that runs onboard a UAV was demonstrated in flight for the first time. It successfully maneuvered the aircraft after a sudden lateral perturbation that models a gust of wind, and processed lidar-derived polyhedral obstacle maps in real time. (5) Tracking of the UAV in the national airspace using the NASA UTM technology was a key safety component of this reference mission, since the flights were conducted beneath the landing approach to a heavily used runway. Comparison to autopilot tracking showed that UTM tracking accurately records the UAV position throughout the flight path.

Moore, Andrew J.↗

NASA NTRS2021

Post-test Inspection of NASA’s Evolutionary Xenon Thruster Long-Duration Test Hardware: Discharge Chamber

The NEXT Long-Duration Test is part of a comprehensive thruster service life assessment intended to demonstrate overall throughput capability, validate service life models, quantify wear rates as a function of time and operating condition, and identify any unknown life-limiting mechanisms. The test was voluntarily terminated in February 2014after demonstrating 51,184 hours of high-voltage operation, 918 kg of propellant throughput, and 35.5 MN-s of total impulse. The post-test inspection of the thruster hardware began shortly afterwards with a combination of non-destructive and destructive analysis techniques, and is presently nearing completion. This paper presents relevant results of the post-test inspection for the discharge chamber as well as other miscellaneous components such as the high-voltage propellant isolators and electrical cabling. Comparison of magnetic field measurements taken during pretest and post-test inspections indicate that the field strength did not degrade, consistent with performance data obtained during the test. Inspection of discharge chamber mesh samples show a deposition coating primarily composed of grid material that is approximately 15 μm in thickness. This thickness is well within the retention capability of the mesh and is therefore not expected to present any issues. Approximately 3.1 grams of deposition flakes were found at the bottom of the discharge chamber, composed primarily of grid material and carbon. Calculated size histograms of these flakes indicate that 99% have a maximum dimension of 200 μm or smaller, which is significantly less than the ion optics grid gap. Larger flakes that are capable of causing a grid-to-grid short will be analyzed to determine if their formation will occur in flight or is a facility effect. The high-voltage propellant isolators as well as numerous other electrical insulators were inspected and no evidence of arcing or any other issues were found.

Rohit Shastry↗

NASA NTRS2021

Porosity Detection and Localization During Composite Cure Inside an Autoclave Using Ultrasonic Inspection

Composite materials offer unique benefits in aerospace applications such as increased strength-to-weight ratio and improved fatigue properties. They are increasingly being used in major commercial aircraft programs. However, current processing methods can lead to defects in composite parts, which must be detected using post-manufacturing inspection methods. Porosity (i.e., pores, voids) is a critical defect from the cure process that is detrimental to performance of the composite part. It is therefore necessary to understand and eliminate the formation of porosity defects. At NASA Langley Research Center, an in-situ cure monitoring system was developed to detect porosity defects as they form in real-time inside an autoclave. A capability to directly detect and localize porosity within a composite during cure did not exist before. This study is focused on an elevated-temperature ultrasonic inspection system to detect porosity defects in composites during autoclave cure. The ultrasonic inspection system operated inside an autoclave within an enclosure cooled by intermittent liquid nitrogen (LN_2) injections. A high-temperature, 2.25 MHz, transducer transmitted ultrasonic waves through the tool plate and into the composite part and measured the amplitude and time of flight of the reflected waves with a 1 mm × 1 mm step size/areal resolution. Porosity was observed via the ultrasonic reflections, which experienced increased attenuation in regions of high porosity. Distinct regions of increased porosity were present due to uneven pressure across the panel, which was driven by an intentional misfit between the flat caul plate and the tapered composite panel with ply drops. The results were validated by post-cure ultrasonic inspection and micrographs. The in-situ inspection system was able to successfully provide porosity detection and localization in the tapered ply-drop panel. The successful results indicate the promise of this system for future implementation in the manufacturing of composite structures for aerospace applications.

Composites↗

NASA NTRS2023

Automated sUAS Inspection Capability for NASA’s Mission Critical Testing Facilities

The wind tunnels at Ames are crucial to NASA and industry but pose unique inspection challenges. Current inspection processes are highly manual, and as such are labor and schedule intensive. These needs can be better met with emerging technology such as sUAS (drones), computer vision, and machine learning. This work seeks to bring the drone based inspection workflow into production-ready status and integrate into existing facility inspections. This includes operation of a drone platform, establishing a photogrammetry pipeline, development of procedures and streamlining flight approval processes, and establishing a base of experience at Ames for this work. We have worked with the NFAC, unitary, and Arcjet facilities to identify use cases and have performed test flights at Ames (both indoors and outdoors). The system is being readied for incorporation into routine inspection operations.

David Daisuke Murakami↗

NASA NTRSDate not supplied

NASA's Office Safety Mission Assurance Efforts to Improve Non-destructive Evaluation Methods for Additive Manufacturing and In-Space Inspection

National Aeronautics and Space Administration (NASA) continues to push the boundary of manned flight. Current mission profiles include flights to the Moon and Mars. Many of these missions require advance manufacturing and planned off planet resource utilization. As NASA continues to develop highly advance materials and manufacturing techniques to meet these mission profiles, inspection of these increasingly complex parts has had to evolve as well. Additive manufacturing is coming to the forefront as a primary manufacturing technique but offers unique challenges when inspection and certification are required. NASA has been working diligently to be a leader in developing and utilizing inspection techniques capable of inspecting these highly advanced parts. Additionally additive manufacturing techniques can also be used to build parts in space and provides a vehicle for in-situ resource utilization for off world missions. As NASA and its commercial crew partners move forward, inspection techniques will need to continue to advance to ensure safe manned space flight. In this talk NASA will highlight many of the advanced nondestructive evaluation efforts going on across the agency, as well as providing highlights for points of infusion for helping NASA meet its future mission goals.

NDE↗

DOE OSTI2025

Multi-Resolution UAV Path Replanning for Inspection of Tailings Dams

Autonomous inspection of large and complex structures with a commercial unmanned aerial vehicle (UAV) is a challenging problem that has been addressed in recent years. In this paper, we address the global motion planning problem of creating autonomous inspection missions for UAVs considering photogrammetry constraints. We focus on the inspection of large tailings dams, which are dam structures used to store waste byproducts of mining. Our method uses a prior sparse point cloud of the dam to generate a voxel grid, where paths satisfying photogrammetry constraints are tested for collisions. We then apply the A* algorithm as a local planner to avoid obstacles within the global mission. Moreover, we address the problem of changing routes online by using octree-based multi-resolution grids for efficient and fast pathfinding. Our results, obtained using tridimensional maps of an actual coal mine tailings dam, show that using octrees for multi-resolution motion planning is faster than using a fixed voxel grid in online missions while inspecting large structures.

42 ENGINEERING↗

NASA NTRS2014

Vision Based Autonomous Robotic Control for Advanced Inspection and Repair

The advanced inspection system is an autonomous control and analysis system that improves the inspection and remediation operations for ground and surface systems. It uses optical imaging technology with intelligent computer vision algorithms to analyze physical features of the real-world environment to make decisions and learn from experience. The advanced inspection system plans to control a robotic manipulator arm, an unmanned ground vehicle and cameras remotely, automatically and autonomously. There are many computer vision, image processing and machine learning techniques available as open source for using vision as a sensory feedback in decision-making and autonomous robotic movement. My responsibilities for the advanced inspection system are to create a software architecture that integrates and provides a framework for all the different subsystem components; identify open-source algorithms and techniques; and integrate robot hardware.

sensory feedback↗

NASA NTRS2020

Laser Based Remote and Rapid Inspection for Composite Plates

Composites have been extensively used in aero structure and become the predominate components in the new airframes. Thus, rapid and effective inspection for composite structures is highly desired in aerospace engineering in order to shorten the certificate cycle for new structures or provide safety guarantee for existing ones. In this paper, a laser based remote Lamb wave inspection system is presented and implemented on composite plates for simulated damage detection. The system employs pulsed laser (PL) and scanning laser Doppler vibrometer (SLDV) for noncontact and remote Lamb wave actuation and wavefield sensing. A composite plate with simulated defect (surface bonded quartz rod) is inspected with the PL-SLDV laser system. Wave scattering are observed in the SLDV acquired wavefield and the damage is further evaluated with wavefield imaging and frequency wavenumber analysis. Potential application towards automatic PL Lamb wave excitation is also explored through employing an industry robotic arm towards rapid inspection.

Lamb waves↗

NASA NTRS1994

A Highly Redundant Robot System for Inspection

The work on the serpentine inspection system at JPL is described. The configuration of the inspection system consists of 20 DOF in total. In particular, the design and development of the serpentine micromanipulator end-effector tool which has 12 DOF is described. The inspection system is used for application in JPL's Remote Surface Inspection project and as a research tool in redundant manipulator control.

robot↗

NASA NTRS1994

Virtual Window Telepresence System for Telerobotics Inspection

Telerobotic inspection can be used in environments that are too hazardous, removed or expensive for direct human inspection. Telerobotic inspection is a complex task requiring an operator to control and coordinate a robot and sensors, while monitoring and interpreting sensor data to detect flaws. A virtual window telepresence system has been developed to aid the operator in performing these inspections.

telepresnece↗