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NASA NTRS2009

A Mode-Shape-Based Fault Detection Methodology for Cantilever Beams

An important goal of NASA's Internal Vehicle Health Management program (IVHM) is to develop and verify methods and technologies for fault detection in critical airframe structures. A particularly promising new technology under development at NASA Langley Research Center is distributed Bragg fiber optic strain sensors. These sensors can be embedded in, for instance, aircraft wings to continuously monitor surface strain during flight. Strain information can then be used in conjunction with well-known vibrational techniques to detect faults due to changes in the wing's physical parameters or to the presence of incipient cracks. To verify the benefits of this technology, the Formal Methods Group at NASA LaRC has proposed the use of formal verification tools such as PVS. The verification process, however, requires knowledge of the physics and mathematics of the vibrational techniques and a clear understanding of the particular fault detection methodology. This report presents a succinct review of the physical principles behind the modeling of vibrating structures such as cantilever beams (the natural model of a wing). It also reviews two different classes of fault detection techniques and proposes a particular detection method for cracks in wings, which is amenable to formal verification. A prototype implementation of these methods using Matlab scripts is also described and is related to the fundamental theoretical concepts.

Tejada, Arturo↗

NASA NTRS2006

Monitoring Temperatures of Tires Using Luminescent Materials

A method of noncontact, optical monitoring of the surface temperature of a tire has been devised to enable the use of local temperature rise as an indication of potential or impending failures. The method involves the use of temperature-sensitive paint (or filler): Temperature-sensitive luminescent dye molecules or other luminescent particles are incorporated into a thin, flexible material coating the tire surface of interest. (Alternatively, in principle, the luminescent material could be incorporated directly into the tire rubber, though this approach has not yet been tested.) The coated surface is illuminated with shorter-wavelength light to excite longer-wavelength luminescence, which is observed by use of a charge-coupled-device camera or a photodetector (see Figure 1). If temporally constant illumination is used, then the temperature can be deduced from the known temperature dependence of the intensity response of the luminescence. If pulsed illumination is used, then the temperature can be deduced from the known temperature dependence of the time or frequency response of the luminescence. If sinusoidally varying illumination is used, then the temperature can be deduced from the known temperature dependence of the phase response of the luminescence. Unlike a prior method of monitoring the temperature at a fixed spot on a tire by use of a thermocouple, this method is not restricted to one spot and can, therefore, yield information on the spatial distribution of temperature: in particular, it enables the discovery of newly forming hot spots where damage may be starting. Also unlike in the thermocouple method, the measurements in this method are not vulnerable to breakage of wires in repeated flexing of the tire. Moreover, unlike in another method in which infrared radiation is monitored as an indication of surface temperature, the luminescence measurements in this method are not significantly affected by changes in infrared emissivity. This method has been demonstrated in application to the outside surface of a tire (see Figure 2), using both constant and pulsed light sources for illumination and cooled, slow-scan, gated CCD cameras for detection. For observing the temperature of the inside surface of a tire (this has not yet been done), it would probably be necessary to use fiber optics and/or windows for coupling excitation light into, and coupling luminescence out of, the interior volume.

Bencic, Timothy J↗

NASA NTRS2019

Evaluation of Wing Load Calibration and Sensing Methods Using Conventional Strain Gages and a Fiber Optic Sensing System Installed on a Straight Tapered Wing

State-of-the-art instrumentation techniques have provided an opportunity to obtain greater insight into structural wing loads during flight. An investigation was undertaken to research new wing instrumentation and load sensing techniques for measuring accurate in-flight spanwise load distributions on wing structures. A straight tapered wing was instrumented with both conventional foil strain gages at five spanwise wing stations and fiber optic strain sensors at every half inch along the entire wing span. Thirty-nine unique load cases were applied to the wing lower surface using hydraulic actuators to obtain various shear, bending moment, and torque load distributions on the wing. This paper will highlight three load calibration approaches. Conventional linear regression calibration methods were applied to foil strain gages providing a single wing station vertical shear, bending moment, and torque load. Linear regression methods were applied to a fiber optic sensing system to provide bending moment and torque spanwise load distributions. A load sensing scheme using strain derived wing shape information derived from a single load case provided vertical shear and bending moment spanwise load distribution information. Aspects of the three different approaches will be compared and contrasted to inform the reader of the benefits or disadvantages of each. Instrument installation, sensor characteristics, test execution aspects, and recommended calibration techniques will be discussed.

structural mechanics↗

NASA NTRS2004

Laser Sounder for Global Measurement of CO2 Concentrations in the Troposphere from Space: Progress

We describe progress toward developing a laser-based technique for the remote measurement of the tropospheric CO2 concentrations from orbit. Our goal is to demonstrate a lidar technique and instrument technology that will permit measurements of the CO2 column abundance in the lower troposphere from aircraft at the few ppm level, with a capability of scaling to permit global CO2 measurements from orbit. Accurate measurements of the tropospheric CO2 mixing ratio from space are challenging due to the many potential error sources. These include possible interference from other trace gas species, the effects of temperature, clouds, aerosols & turbulence in the path, changes in surface reflectivity, and variability in dry air density caused by changes in atmospheric pressure, water vapor and topographic height. Some potential instrumental errors include frequency drifts in the transmitter, small transmission and sensitivity drifts in the instrument. High signal-to-noise ratios and measurement stability are needed for mixing ratio estimates at the few ppm level. We have been developing a laser sounder approach as a candidate for a future space mission. It utilizes multiple different laser transmitters to permit simultaneous measurement of CO2 and O2 extinction, and aerosol backscatter in the same measurement path. It directs the narrow co-aligned laser beams from the instrument's fiber lasers toward nadir, and measures the energy of the strong laser echoes reflected from the Earth's land and water surfaces. During the measurement its narrow linewidth lasers are rapidly tuned on- and off- selected CO2 line near 1572 nm and an O2 absorption line near 770 nm. The receiver measures the energies of the laser echoes from the surface and any clouds and aerosols in the path with photon counting detectors. Ratioing the on- to off-line echo pulse energies for each gas permits the column extinction and column densities of CO2 and O2 to be estimated simultaneously via the differential absorption lidar technique. For the on-line wavelengths, the side of the selected absorption lines are used, which due to pressure broadening, weights the measurements to the lower troposphere, where CO2 variations caused by surface sources and sinks are largest. Simultaneous measurements of O2 column abundance are made using an identical approach using an O2 line. The laser backscatter profiles from clouds and aerosols are measured with other lidar channels, which permits identifying measurements influenced by clouds and/or aerosol scattering in the path. For space use, our lidar would continuously measure at nadir in near polar circular orbit. Using dawn and dusk measurements made over the same region will make it possible to sample the diurnal variations in CO2 mixing ratios. A 1-m diameter telescope is used for the receiver for all wavelengths. When averaging over 50 seconds, our calculations show a SNR of approximately 1500 is achievable for each gas at each on- and off-line measurement. Measurements from such a mission can be used to generate monthly global maps of the lower tropospheric CO2 column abundance. Our calculations show global coverage with an accuracy of a few ppm with a spatial resolution of approximately 50,000 sq. km are achievable each month. We have demonstrated some key elements of the laser, detector and receiver approaches in the laboratory and with measurements over a 206 m horizontal path. These include stable measurements of CO2 line shapes in an absorption cell using a fiber laser amplifier seeded by a tunable diode laser, measurement of small amplitude changes at low optical signal levels with the PMT receiver, and comparison of the horizontal path measurements of CO2 against those from an in-situ instrument.

Abshire, J. B.↗

NASA NTRS1977

A fundamental approach to adhesion: Synthesis, surface analysis, thermodynamics and mechanics

The ability of SEM/EDAX to determine the physical and chemical composition of very small areas was used to study several diverse types of samples representative of NASA-LaRC technology. More systematic investigation was carried out on differences in the results of grit-blasting Ti 6-4 adherends and the presence of extraneous elements, primarily silicon, in some polymer/HT-S fiber composites. Initial results were obtained from a fractured (ILS) short-beam shear specimen, and from Ti 6-4 alloy, before and after a proprietary Boeing anodizing surface preparation for adhesive bonding. Photomicrographs and EDAX spectra were also obtained from new, fractured lap shear strength specimens that employed PPQ and LARC-13 adhesives.

Dwight, D. W.↗

NASA NTRS2010

Boundary Layer Measurements in a Supersonic Wind Tunnel Using Doppler Global Velocimetry

A modified Doppler Global Velocimeter (DGV) was developed to measure the velocity within the boundary layer above a flat plate in a supersonic flow. Classic laser velocimetry (LV) approaches could not be used since the model surface was composed of a glass-ceramic insulator in support of heat-transfer measurements. Since surface flare limited the use of external LV techniques and windows placed in the model would change the heat transfer characteristics of the flat plate, a novel approach was developed. The input laser beam was divided into nine equal power beams and each transmitted through optical fibers to a small cavity within the model. The beams were then directed through 1.6-mm diameter orifices to form a series of orthogonal beams emitted from the model and aligned with the tunnel centerline to approximate a laser light sheet. Scattered light from 0.1-micron diameter water condensation ice crystals was collected by four 5-mm diameter lenses and transmitted by their respective optical fiber bundles to terminate at the image plane of a standard two-camera DGV receiver. Flow measurements were made over a range from 0.5-mm above the surface to the freestream at Mach 3.51 in steady state and heat pulse injected flows. This technique provides a unique option for measuring boundary layers in supersonic flows where seeding the flow is problematic or where the experimental apparatus does not provide the optical access required by other techniques.

Meyers, James F.↗

NASA NTRS1994

A fiber matrix model for fluid flow and streaming potentials in the canaliculi of an osteon

A theoretical model is developed to predict the fluid shear stress and streaming potential at the surface of osteocytic processes in the lacunar-canalicular porosity of an osteon when the osteon is subject to mechanical loads that are parallel or perpendicular to its axis. The theory developed in Weinbaum et al. (31) for the flow through a proteoglycan matrix in a canaliculus is employed in a poroelastic model for the osteon. Our formulation is a generalization of that of Petrov et al. (17). Our model predicts that, in order to satisfy the measured frequency dependence of the phase and magnitude of the SGP in macroscopic bone samples, the fiber spacing in the fluid annulus must lie in the narrow range 6-7 nm typical of the spacing of GAG sidechains along a protein monomer. The model predictions for the local SGP profiles in the osteon agree with the experimental observations of Starkebaum et al. (24). The theory predicts that the pore pressure relaxation time, tau d, for a 150-300 microns diameter osteon with the foregoing matrix structure is approximately 0.03-0.13 sec, and that the amplitude of the mean fluid shear stress on the membrane of the osteocytic process at the mean areal radius of the osteon has a maximum at 28 Hz if tau d = 0.06 sec. This maximum, which is independent of the magnitude of the loading, could be important in vivo since the recent experiments of Turner et al. (28) and McLeod et al. (15) have a peak in the strain frequency spectrum between 20 and 30 Hz that also appears to be independent of the type (magnitude) of loading. Numerical predictions for the amplitude of the average fluid shear stress on the osteocytic membrane at the mean areal radius of the osteon show that the fluid shear stress associated with the low amplitude 20-30 Hz spectral strain component is at least as large as the average fluid shear stress associated with the high amplitude 1 Hz stride component, although the latter loading is an order of magnitude larger, and has a magnitude that lies within the middle of the range, 6-30 dynes/cm2, where fluid shear stresses in tissue culture studies with osteoblast monolayers have elicited an intracellular Ca++ response (31). The implications of these results for intracellular electrical communication are discussed.

Non-NASA Center↗

NASA NTRS2004

Freeze Tolerant Radiator for an Advanced EMU

During an Extravehicular Activity (EVA), the astronaut s metabolic heat and the heat produced by the Portable Life Support Unit (PLSS) must be rejected. This heat load is currently rejected by a sublimator, which vents up to eight pounds of water each EVA. However, for advanced space missions of the future, water venting to space needs to be minimized because resupply impacts from earth will be prohibitive. If this heat load could be radiated to space from the PLSS, which has enough surface area to radiate most of the heat, the amount of water now vented could be greatly reduced. Unfortunately, a radiator rejects heat at a relatively constant rate, but the astronauts generate a variable heat load depending on how hard they are working. Without a way to vary the heat removal rate, the astronaut would experience cold discomfort or even frostbite. A proven method allowing a radiator to be turned-down is to sequentially allow tubes that carry the heat transfer fluid to the radiator to freeze. A drawback of current freezable radiators using this method is that they are far to heavy for use on a PLSS, because they use heavy construction to prevent the tubes from bursting as they freeze and thaw. This creates the need for a large radiator to reject most of the heat but with a lightweight tube that doesn t burst as it freezes and thaws. The new freezable radiator for the Extravehicular Mobility Unit (EMU) has features to accommodate the expansion of the radiator fluid when it freezes, and still have the high tube to fin conductance needed to minimize the number and weight of the tubes. Radiator fluid candidates are water and a propylene glycol-water mixture. This design maintains all materials within their elastic limits so that large volume changes can be achieved without breaking the tube. This concept couples this elastic expansion with an extremely lightweight, extremely high conductivity carbon fiber fin that can carry the heat needed to thaw a frozen tube. By using most of the exposed surface area of the PLSS as a radiator, the system can reject about 75% of the highest heat load, and reduce the loss of water through sublimation by a factor of four. The proposed radiator and a small water tank can be no heavier than the current system.

Copeland, Robert J.↗

NASA NTRS1999

Chemical Sensors Based on IR Spectroscopy and Surface-Modified Waveguides

Sol-gel processing techniques have been used to apply thin porous films to the surfaces of planar infrared (IR) waveguides to produce widely useful chemical sensors. The thin- film coating serves to diminish the concentration of water and increase the concentration of the analyte in the region probed by the evanescent IR wave. These porous films are composed of silica, and therefore, conventional silica surface modification techniques can be used to give the surface a specific functional character. The sol-gel film was surface-modified to make the film highly hydrophobic. These sensors were shown to be capable of detecting non-polar organic analytes, such as benzonitrile, in aqueous solution with detection limits in the ppb range. Further, these porous sol-gel structures allow the analytes to diffuse into and out of the films rapidly, thus reaching equilibrium in less than ten seconds. These sensors are unique because of the fact that their operation is based on the measurement of an IR absorption spectrum. Thus, these sensors are able to identify the analytes as well as measure concentration with high sensitivity. These developments have been documented in previous reports and publications. Recently, we have also targeted detection of the polar organic molecules acetone and isopropanol in aqueous solution. Polar organics are widely used in industrial and chemical processes, hence it is of interest to monitor their presence in effluents or decontamination process flows. Although large improvements in detection limits were expected with non-polar organic molecules in aqueous solutions using very hydrophobic porous sol-gel films on silicon attenuated total reflectance (Si ATR) waveguides, it was not as clear what the detection enhancements might be for polar organic molecules. This report describes the use of modified sol-gel-coated Si ATR sensors for trace detection and quantitation of small polar organic molecules in aqueous solutions. The detection of both acetone and isopropanol molecules in aqueous solution has been previously reported for chalcogenide fiber optic sensors. The sol-gel film was produced using a mixture of ethyltriethoxysilane and tetraethoxysilane and the surface modification was carried out using trimethylchlorosilane. We have demonstrated that this film concentrates the target polar analytes from aqueous solution in the region probed by the evanescent wave to improve detection limits by as much as a factor of 450.

Lopez, Gabriel P.↗

NASA NTRS2004

The Influence of Sizings on the Durability of High-Temperature Polymer Composites

To increase performance and durability of high-temperature composites for potential rocket engine components, it is necessary to optimize wetting and interfacial bonding between high modulus carbon fibers and high-temperature polyimide resins. Sizings commercially supplied on most carbon fibers are not compatible with polyimides. In this study, the chemistry of sizings on two high-modulus carbon fibers (M40J and M60J, Toray) was characterized as was the chemistry of PMR-II-50 fluorinated polyimide resin. The carbon fibers were characterized using single filament wetting, scanning electron microscopy, fourier transform infrared spectroscopy, and x-ray photoelectron spectroscopic measurements. The polyimide matrix resins were coated onto glass filaments for characterization by wetting measurements. Surface energy components were obtained by wetting with nondispersive (methylene iodide), acidic (ethylene glycol), and basic (formamide) probes. A continuous desizing system that uses an environmentally friendly chemical-mechanical process was developed for tow level fiber. Composites were fabricated with fibers containing the manufacturer's sizing, desized, and further treated with a reactive finish. Results of room-temperature tests after thermal aging show that the reactive finish produces a higher strength and more durable interface compared to the manufacturer's sizing. When exposed to moisture blistering tests, however, the better bonded composite displayed a tendency to delaminate, presumably due to trapping of volatiles.

Allred, Ronald E.↗

NASA NTRSDate not supplied

Integration of Design Data Into Automated Fiber Placement Process Planning Metrics

With the ever-expanding aviation industry, a need is arising for more rapid production of composite aircraft to meet increasing demand. State-of-the-art aircraft such as the Boeing 787showcase 50% composite material usage by weight, highlighting this emerging industry-wide adoption of the material system. Currently, many of the large structures associated with these aircraft are manufactured additively via Automated Fiber Placement (AFP). The AFP process shows great potential for efficient manufacturing, however unavoidable defects still occur because of tool surface geometry, placement errors, or poor process planning, resulting in decreased quality and throughput. Due to such effects, it is critical to incorporate design for manufacturing (DFM) principles to achieve the optimal manufacturing plan and resulting structure. This work will develop a methodology for incorporating design information into process planning metrics in an automated fashion to achieve an optimal set of process inputs.The analysis incorporates HyperX, Computer Aided Process Planning (CAPP) and Vericut Composite Programming (VCP). Safety margins from HyperX are imported into CAPP where AFP defects are mapped to the values. The resulting margins are then incorporated into the CAPP manufacturability algorithms, creating a design informed process planning analysis

Automated Fiber Placement↗

NASA NTRS1973

Optimization of Rei-mullite Physical Properties

Micromechanical and thermal modeling studies prove that ceramic fiber mullite materials is the only system capable of shuttle thermal protection to 1644 K. Hafnia pigmentated mullite surface coatings meet both orbital and reentry thermal radiative requirements for reuse without refurbishment. Thermal and mechanical models show growths potentials associated with the mullite system for a factor of 2 improvement in mechanical properties, and a factor of 2 to 3 reduction in thermal conductivity.

Tanzilli, R. A.↗

NASA NTRS1984

Surface roughness studies with DALLAS-detector array for laser light angular scattering

An attempt is made to develop a better mathematical description of optical scattering phenomena, in order to construct an optical scattering apparatus for reliable and routine measurements of roughness parameters without resorting to comparator standards. After a brief outline of optical scattering theory, a description is presented of an experimental instrument for measuring surface roughness which incorporates optical scattering principles. The instrument has a He-Ne laser which illuminates the test surface at a variable angle of incidence. Scattered light distribution is detected by an array of 87 fiber-optic sensors positioned in a rotating semicircular yoke. The output from the detector is digitized and analyzed in a laboratory computer. For a comparison with experimental data, theoretical distributions are calculated by substituting the roughness profiles into the operand of and integral equation for electromagnetic scattering developed by Beckmann and Spizzichino (1963). A schematic diagram of the instrument is provided and the general implications of the experimental results are discussed.

Vorburger, T. V.↗

NASA NTRS1991

Evaluation of long-duration exposure to the natural space environment on graphite-polyimide and graphite-epoxy mechanical properties

Experiment AO175 involved passive exposure (on oblique leading and trailing faces of LDEF) of carbon-fiber reinforced laminates of epoxy, bismaleimide, and polyimide resins. Post-flight evaluation included: optical examination of exposed surfaces, panel weight and distortion measurements, ultrasonic c-scan inspection, and conventional mechanical testing of coupons machined from the panel.

Vyhnal, Richard F.↗

NASA NTRS1995

Surface contamination analysis technology team overview

A team was established which consisted of representatives from NASA (Marshall Space Flight Center and Langley Research Center), Thiokol Corporation, the University of Alabama in Huntsville, AC Engineering, SAIC, Martin Marietta, and Aerojet. The team's purpose was to bring together the appropriate personnel to determine what surface inspection techniques were applicable to multiprogram bonding surface cleanliness inspection. In order to identify appropriate techniques and their sensitivity to various contaminant families, calibration standards were developed. Producing standards included development of consistent low level contamination application techniques. Oxidation was also considered for effect on inspection equipment response. Ellipsometry was used for oxidation characterization. Verification testing was then accomplished to show that selected inspection techniques could detect subject contaminants at levels found to be detrimental to critical bond systems of interest. Once feasibility of identified techniques was shown, selected techniques and instrumentation could then be incorporated into a multipurpose inspection head and integrated with a robot for critical surface inspection. Inspection techniques currently being evaluated include optically stimulated electron emission (OSEE); near infrared (NIR) spectroscopy utilizing fiber optics; Fourier transform infrared (FTIR) spectroscopy; and ultraviolet (UV) fluorescence. Current plans are to demonstrate an integrated system in MSFC's Productivity Enhancement Complex within five years from initiation of this effort in 1992 assuming appropriate funding levels are maintained. This paper gives an overview of work accomplished by the team and future plans.

Burns, H. Dewitt↗

NASA NTRS1999

Fiber Optic Microphone

Research into advanced pressure sensors using fiber-optic technology is aimed at developing compact size microphones. Fiber optic sensors are inherently immune to electromagnetic noise, and are very sensitive, light weight, and highly flexible. In FY 98, NASA researchers successfully designed and assembled a prototype fiber-optic microphone. The sensing technique employed was fiber optic Fabry-Perot interferometry. The sensing head is composed of an optical fiber terminated in a miniature ferrule with a thin, silicon-microfabricated diaphragm mounted on it. The optical fiber is a single mode fiber with a core diameter of 8 micron, with the cleaved end positioned 50 micron from the diaphragm surface. The diaphragm is made up of a 0.2 micron thick silicon nitride membrane whose inner surface is metallized with layers of 30 nm titanium, 30 nm platinum, and 0.2 micron gold for efficient reflection. The active sensing area is approximately 1.5 mm in diameter. The measured differential pressure tolerance of this diaphragm is more than 1 bar, yielding a dynamic range of more than 100 dB.

Cho, Y. C.↗

NASA NTRS2004

Performance of Nanotube-Based Ceramic Composites: Modeling and Experiment

The excellent mechanical properties of carbon-nanotubes are driving research into the creation of new strong, tough nanocomposite systems. In this program, our initial work presented the first evidence of toughening mechanisms operating in carbon-nanotube- reinforced ceramic composites using a highly-ordered array of parallel multiwall carbon-nanotubes (CNTs) in an alumina matrix. Nanoindentation introduced controlled cracks and the damage was examined by SEM. These nanocomposites exhibit the three hallmarks of toughening in micron-scale fiber composites: crack deflection at the CNT/matrix interface; crack bridging by CNTs; and CNT pullout on the fracture surfaces. Furthermore, for certain geometries a new mechanism of nanotube collapse in shear bands was found, suggesting that these materials can have multiaxial damage tolerance. The quantitative indentation data and computational models were used to determine the multiwall CNT axial Young's modulus as 200-570 GPa, depending on the nanotube geometry and quality.

Curtin, W. A.↗

NASA NTRS2008

Assessment of Composite Delamination Self-Healing Via Micro-Encapsulation

Composite skin/stringer flange debond specimens manufactured from composite prepreg containing interleaf layers with a polymer based healing agent encapsulated in thin walled spheres were tested. As a crack develops and grows in the base polymer, the spheres fracture releasing the healing agent. The agent reacts with catalyst and polymerizes healing the crack. In addition, through-thickness reinforcement, in the form of pultruded carbon z-pins were included near the flange tips to improve the resistance to debonding. Specimens were manufactured with 14 plies in the skin and 10 plies in the stiffener flange. Three-point bend tests were performed to measure the skin/stiffener debonding strength and the recovered strength after healing. The first three tests performed indicated no healing following unloading and reloading. Micrographs showed that delaminations could migrate to the top of the interleaf layer due to the asymmetric loading, and hence, bypass most of the embedded capsules. For two subsequent tests, specimens were clamped in reverse bending before reloading. In one case, healing was observed as evidenced by healing agent that leaked to the specimen edge forming a visible "scar". The residual strength measured upon reloading was 96% of the original strength indicating healing had occurred. Hence, self-healing is possible in fiber reinforced composite material under controlled conditions, i.e., given enough time and contact with pressure on the crack surfaces. The micro-encapsulation technique may prove more robust when capsule sizes can be produced that are small enough to be embedded in the matrix resin without the need for using an interleaf layer. However, in either configuration, the amount of healing that can occur may be limited to the volume of healing agent available relative to the crack volume that must be filled.

O'Brien, T. Kevin↗