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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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All sources NASA NTRS DOE OSTI

NASA NTRS1991

Software component quality evaluation

The paper describes a software inspection process that can be used to evaluate the quality of software components. Quality criteria, process application, independent testing of the process and proposed associated tool support are covered. Early results indicate that this technique is well suited for assessing software component quality in a standardized fashion. With automated machine assistance to facilitate both the evaluation and selection of software components, such a technique should promote effective reuse of software components.

Clough, A. J.↗

NASA NTRS1995

Product Assurance for Spaceflight Hardware

This report contains information about the tasks I have completed and the valuable experience I have gained at NASA. The report is divided into two different sections followed by a program summary sheet. The first section describes the two reports I have completed for the Office of Mission Assurance (OMA). I describe the approach and the resources and facilities used to complete each report. The second section describes my experience working in the Receipt Inspection/Quality Assurance Lab (RI/QA). The first report described is a Product Assurance Plan for the Gas Permeable Polymer Materials (GPPM) mission. The purpose of the Product Assurance Plan is to define the various requirements which are to be met through completion of the GPPM mission. The GPPM experiment is a space payload which will be flown in the shuttle's SPACEHAB module. The experiment will use microgravity to enable production of complex polymeric gas permeable materials. The second report described in the first section is a Fracture Analysis for the Mir Environmental Effects Payload (MEEP). The Fracture Analysis report is a summary of the fracture control classifications for all structural elements of the MEEP. The MEEP hardware consists of four experiment carriers, each of which contains an experiment container holding a passive experiment. The MEEP hardware will be attached to the cargo bay of the space shuttle. It will be transferred by Extravehicular Activity and mounted on the Mir space station. The second section of this report describes my experiences in the RVQA lab. I listed the different equipment I used at the lab and their functions. I described the extensive inspection process that must be completed for spaceflight hardware. Included, at the end of this section, are pictures of most of the equipment used in the lab. There is a summary sheet located at the end of this report. It briefly describes the valuable experience I have gained at NASA this summer and what I will be able to take with me as I return to college. I briefly discuss the experiences I mentioned in the previous three paragraphs along with training classes I attended and courses I completed at the Learning Lab.

Monroe, Mike↗

NASA NTRS1998

Thermographic Inspection of Metallic Honeycomb Sandwich Structures

The X-33/VentureStar has a Thermal Protection System (TPS) consisting mainly of brazed metallic honeycomb sandwich structures. Inspection of these structures is changing as a result of the extremely thin (less than 200 microns) skins, the small critical defect size (less than 2 mm long by 100 microns wide) and the large number (more than 1000) of parts to be inspected. Pulsed Infrared Thermography has been determined to be the most appropriate inspection method for manufacturing inspection based on performance comparison with other methods, cost, schedule and other factors. The results of the assessment of the different methods will be summarized and data on the performance of the final production inspection system will be given. Finite difference thermal methods have been used to model the whole inspection process. Details of correlation between the models and experimental data will be given and data on the use of pulsed infrared thermography on other metallic honeycomb sandwich structures will be given.

Taylor, John O.↗

NASA NTRS1998

Thermographic Qualification of Graphite/Epoxy Instrumentation Racks

A nondestructive evaluation method is desired for ensuring the 'as manufactured' and 'post service' quality of graphite/epoxy instrumentation rack shells. The damage tolerance and geometry of the racks dictate that the evaluation method be capable of identifying defects, as small as 0.25 inch 2 in area, over large acreage regions, tight compound radii and thickness transition zones. The primary defects of interest include voids, inclusions, delaminations and porosity. The potential for an infrared thermographic inspection to replace ultrasonic testing, for qualifying the racks as 'defect free' is under investigation. The inspection process is validated by evaluating defect standard panels built to the same specifications as the racks, except for the insertion of artificial fabricated defects. The artificial defects are designed to match those which are most prevalent in the actual instrumentation racks. A target defect area of 0.0625 inch 2 (a square with 0.25 inch on a side) was chosen for the defect standard panels to ensure the ability to find all defects of the critical (0.25 inch squared) size.

Walker, James L.↗

NASA NTRS2002

Evolutionary Design of a Robotic Material Defect Detection System

During the post-flight inspection of SSME engines, several inaccessible regions must be disassembled to inspect for defects such as cracks, scratches, gouges, etc. An improvement to the inspection process would be the design and development of very small robots capable of penetrating these inaccessible regions and detecting the defects. The goal of this research was to utilize an evolutionary design approach for the robotic detection of these types of defects. A simulation and visualization tool was developed prior to receiving the hardware as a development test bed. A small, commercial off-the-shelf (COTS) robot was selected from several candidates as the proof of concept robot. The basic approach to detect the defects was to utilize Cadmium Sulfide (CdS) sensors to detect changes in contrast of an illuminated surface. A neural network, optimally designed utilizing a genetic algorithm, was employed to detect the presence of the defects (cracks). By utilization of the COTS robot and US sensors, the research successfully demonstrated that an evolutionarily designed neural network can detect the presence of surface defects.

Ballard, Gary↗

NASA NTRS2004

Compact Microscope Imaging System With Intelligent Controls Improved

The Compact Microscope Imaging System (CMIS) with intelligent controls is a diagnostic microscope analysis tool with intelligent controls for use in space, industrial, medical, and security applications. This compact miniature microscope, which can perform tasks usually reserved for conventional microscopes, has unique advantages in the fields of microscopy, biomedical research, inline process inspection, and space science. Its unique approach integrates a machine vision technique with an instrumentation and control technique that provides intelligence via the use of adaptive neural networks. The CMIS system was developed at the NASA Glenn Research Center specifically for interface detection used for colloid hard spheres experiments; biological cell detection for patch clamping, cell movement, and tracking; and detection of anode and cathode defects for laboratory samples using microscope technology.

McDowell, Mark↗

NASA NTRS2009

Technology Infusion of CodeSonar into the Space Network Ground Segment

This slide presentation reviews the applicability of CodeSonar to the Space Network software. CodeSonar is a commercial off the shelf system that analyzes programs written in C, C++ or Ada for defects in the code. Software engineers use CodeSonar results as an input to the existing source code inspection process. The study is focused on large scale software developed using formal processes. The systems studied are mission critical in nature but some use commodity computer systems.

Benson, Markland J.↗

NASA NTRS2011

Mission Operations Directorate - Success Legacy of the Space Shuttle Program (Overview of the Evolution and Success Stories from MOD During the Space Shuttle program)

In support of the Space Shuttle Program, as well as NASA's other human space flight programs, the Mission Operations Directorate (MOD) at the Johnson Space Center has become the world leader in human spaceflight operations. From the earliest programs - Mercury, Gemini, Apollo - through Skylab, Shuttle, ISS, and our Exploration initiatives, MOD and its predecessors have pioneered ops concepts and emphasized a history of mission leadership which has added value, maximized mission success, and built on continual improvement of the capabilities to become more efficient and effective. This paper provides specific examples that illustrate how MOD's focus on building and contributing value with diverse teams has been key to their successes both with the US space industry and the broader international community. This paper will discuss specific examples for the Plan, Train, Fly, and Facilities aspects within MOD. This paper also provides a discussion of the joint civil servant/contractor environment and the relative badge-less society within MOD. Several Shuttle mission related examples have also been included that encompass all of the aforementioned MOD elements and attributes, and are used to show significant MOD successes within the Shuttle Program. These examples include the STS-49 Intelsat recovery and repair, the (post-Columbia accident) TPS inspection process and the associated R-Bar Pitch Maneuver for ISS missions, and the STS-400 rescue mission preparation efforts for the Hubble Space Telescope repair mission. Since their beginning, MOD has consistently demonstrated their ability to evolve and respond to an ever changing environment, effectively prepare for the expected and successfully respond to the unexpected, and develop leaders, expertise, and a culture that has led to mission and Program success.

Azbell, Jim A.↗

NASA NTRS2012

Modeling the Effects of Beam Size and Flaw Morphology on Ultrasonic Pulse/Echo Sizing of Delaminations in Carbon Composites

The size and shape of a delamination in a multi-layered structure can be estimated in various ways from an ultrasonic pulse/echo image. For example the -6dB contours of measured response provide one simple estimate of the boundary. More sophisticated approaches can be imagined where one adjusts the proposed boundary to bring measured and predicted UT images into optimal agreement. Such approaches require suitable models of the inspection process. In this paper we explore issues pertaining to model-based size estimation for delaminations in carbon fiber reinforced laminates. In particular we consider the influence on sizing when the delamination is non-planar or partially transmitting in certain regions. Two models for predicting broadband sonic time-domain responses are considered: (1) a fast "simple" model using paraxial beam expansions and Kirchhoff and phase-screen approximations; and (2) the more exact (but computationally intensive) 3D elastodynamic finite integration technique (EFIT). Model-to-model and model-to experiment comparisons are made for delaminations in uniaxial composite plates, and the simple model is then used to critique the -6dB rule for delamination sizing.

Margetan, Frank J.↗

NASA NTRSDate not supplied

Realistic Thermographic Simulation of Impact Damage with Quadrupole Method

Flash thermography has been shown to be an effective method for detection of delaminations in carbon fiber reinforced polymer (CFRP) composite structures. Improved understanding of the limitations of the technique can be obtained by simulating the inspection process. Time domain finite difference and finite element methods are well suited for such simulations but can be computationally intensive. An alternate method is to solve the Laplace transform of the heat equation, then invert the Laplace transform to produce a time domain response. Often this is referred to as the thermal quadrupole method and is well suited for simulating flash thermography. The quadrupole method has been used extensively for simulating one-dimensional heat flow in multilayer systems with contact resistances at the interfaces. It is also applicable for three dimensional configurations, in particular for simulation of changes in thermographic response due to delaminations in composites. This presentation discusses three-dimensional simulations with realistic shapes and contact resistances at the interfaces between layers. The results of these simulations are compared to thermography measurements on composites specimens with impact induced delaminations.

thermography↗

NASA NTRSDate not supplied

Realistic Thermographic Simulation of Impact Damage with Quadrupole Method

Flash thermography has been shown to be an effective method for detection of delaminations in carbon fiber reinforced polymer (CFRP) composite structures. Improved understanding of thelimitations of the technique can be obtained by simulating the inspection process. Time domainfinite difference and finite element methods are well suited for such simulations but can be computationally intensive. An alternate method is to solve the Laplace transform of the heat equation, then invert the Laplace transform to produce a time domain response. Often this is referred to as the thermal quadrupole method and is well suited for simulating flash thermography. The quadrupole method has been used extensively for simulating one-dimensional heat flow in multilayer systems with contact resistances at the interfaces. It is also applicable for three dimensional configurations, in particular for simulation of changes in thermographic response due to delaminations in composites. This presentation discusses three-dimensional simulations with realistic shapes and contact resistances at the interfaces between layers. The results of these simulations are compared to thermography measurements on composites specimens with impact induced delaminations.

Thermography↗

NASA NTRS2019

Thermally-resilient image sensor packaging approach for Mars2020 enhanced engineering cameras

We will present the steps taken to derive the thermally-resilient electronics packaging design of the Mars2020 EECAM detector. We will highlight analyses and empirical test results that lead to a wide-temperature-survivable COTS component packaging design. Details of thermal cycle testing, in-process inspections, and final packaging design will be presented.

Howard, Sean↗

NASA NTRS1988

A generic expert system for materials processing in space

A generic expert system is described for inspecting materials processed in space (MPS). The system may be applied, with the appropriate knowledge base, to any of the nondestructive testing methods (NDT) which are appropriate to MPS. Regardless of the method being used, the inspection process consists of three tasks: (1) signal or image processing of the NDT output and feature extraction, (2) interpretation of features in terms of MPS discontinuities, and (3) evaluation of the quality of the MPS based upon industry standards. In contrast to rule based systems, this system represents its knowledge as multidimensional vectors and appropriate functions on them. Currently, the expert system accepts manual input of observed features. Once the expert system has been tested and compared to human expert inspectors, a vision front-end will be developed to complete automation of the expert MPS inspection system, based on visual discontuities. Then the data base will be extended to include a variety of other NDT methods. In addition to functional performance, ease of use was established through menu window driven input as well as flexibility in building, using and modifying data bases for different applications.

Andersen, Kristinn↗

NASA NTRS2008

Taking the Heat: Handling the Shuttle's RCC Wing Panels

Innovative inspection technology was developed to inspect the Reinforced Carbon-Carbon (RCC) wing panels on the vehicle, thus eliminating need to remove/reinstall all 44 RCC panels for inspections per processing flow. Manually holding inspection tools up to the RCC panels was a 3-person job with high risk of personnel injury and flight hardware damage. To further enhance ergonomics, reduce personnel/flight hardware risks, and improve repeatability, an inspection cart and fixture were constructed to physically secure the instruments for Inspectors during 652 inspection points per flow. The electric lift used to handle RCCs was also utilized to raise the heavy, bulky inspection equipment up to the wing leading edge.

Stegles, Katrine S.↗

NASA NTRS1981

Development and demonstration of manufacturing processes for fabricating graphite/LARC 160 polyimide structural elements

The development and demonstration of manufacturing technologies for the structural application of Celion graphite/LARC-160 polyimide composite material is discussed. Process development and fabrication of demonstration components are discussed. Process development included establishing quality assurance of the basic composite material and processing, nondestructive inspection of fabricated components, developing processes for specific structural forms, and qualification of processes through mechanical testing. Demonstration components were fabricated. The demonstration components consisted of flat laminates, skin/stringer panels, honeycomb panels, chopped fiber compression moldings, and a technology demonstrator segment (TDS) representative of the space shuttle aft body flap.

Frost, R. K.↗

DOE OSTI2026

Virtual Inspection of Advanced Manufacturing via Process-Scale Digital Twins (Abbreviated Report)

Inspection and certification comprise the most significant bottlenecks in advanced manufacturing for NNSA applications, often requiring far more time and resources than the fabrication of the parts themselves. Traditional methods, such as manual review and X-ray computed tomography, are not only slow and costly, but also struggle to provide a clear connection between manufacturing instructions and the final performance of critical components. This gap limits both the agility and assurance needed to support the modernization and safety of the United States nuclear stockpile. In response, our Strategic Initiative established a digital twin framework that integrates realtime process monitoring, automated data analysis, and immersive virtual reality collaboration into a unified inspection pipeline. By leveraging data from sensors, machine instructions, and imaging, we created high-fidelity virtual models of manufactured parts that could be rapidly analyzed and certified. This approach was first demonstrated with Direct Ink Write, and then extended to other manufacturing settings, including conventional (or “subtractive”) manufacturing and to predict the end of life performance of parts per the aging and lifetimes programs. The result is a transformational capability: inspection times have been reduced by a factor of 120,000 without loss of accuracy and while simultaneously improving traceability and confidence in part quality. This framework not only streamlines certification for critical applications, but also positions the national security enterprise to respond more flexibly to emerging challenges, supporting agile manufacturing and digital engineering practices across a broad range of mission-relevant domains.

42 ENGINEERING↗

NASA NTRS1998

Automation of the Image Analysis for Thermographic Inspection

Several data processing procedures for the pulse thermal inspection require preliminary determination of an unflawed region. Typically, an initial analysis of the thermal images is performed by an operator to determine the locations of unflawed and the defective areas. In the present work an algorithm is developed for automatically determining a reference point corresponding to an unflawed region. Results are obtained for defects which are arbitrarily located in the inspection region. A comparison is presented of the distributions of derived values with right and wrong localization of the reference point. Different algorithms of automatic determination of the reference point are compared.

Plotnikov, Yuri A.↗

NASA NTRS1983

Practical preventive reliability using matrix forms

This paper describes a practical new tool to improve the reliability of equipment. It uses a matrix form to help monitor anticipated component faults precisely. The tool provides the practical measures necessary to generate matrix tables that accurately display all causes of failure and all planned programmatic analyses, tests, processes, and inspections. When completed, the matrix tables give users in-depth visibility of the degree of protection against component failure that is provided by the program's preventive measure plans. The matrix form is an excellent technique for tracking, and thereby influencing, the reliability of nonelectronic spacecraft subsystems or components. No electronic applications have been tried, but the procedure can be useful in the electronics field, e.g., in integrated circuit production planning, and perhaps in process control, inspection or test lines for other electronic components. The drawing of forms, and the recording/manipulation of the data can be computerized.

Johnson, S. A.↗