Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Defect detection”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

NDE of thermal protection system for space shuttle solid rocket booster

Potential nondestructive test (NDE) methods were evaluated for detecting debonds and weak bonds in the thermal protection system (TPS) for the space shuttle solid rocket boosters. The primary thermal protection material is a sprayable, thick epoxy coating that is filled with lightweight and thermal insulating materials. Test panels were fabricated with a wide variety of hidden realistic defects, including contact debonds and weak bonds. Nondestructive test results were obtained. Candidate NDE methods evaluated for booster production applications include laser interferometry (e.g., electronic shearography), infrared thermography, radiography (e.g., computed tomography), acousto-ultrasonics, mechanical/acoustic impedance, ultrasonics, acoustic emission, and the tap test. Capabilities, advantages, disadvantages, and relative performances in defect detection of each test method for TPS bonding applications are reported. Electronic shearography NDE was technically the superior method for detecting debonds.

Myers, R. S.↗
NASA NTRS2012

Fiber Bragg Grating Sensor System for Monitoring Smart Composite Aerospace Structures

Lightweight, electromagnetic interference (EMI) immune, fiber-optic, sensor- based structural health monitoring (SHM) will play an increasing role in aerospace structures ranging from aircraft wings to jet engine vanes. Fiber Bragg Grating (FBG) sensors for SHM include advanced signal processing, system and damage identification, and location and quantification algorithms. Potentially, the solution could be developed into an autonomous onboard system to inspect and perform non-destructive evaluation and SHM. A novel method has been developed to massively multiplex FBG sensors, supported by a parallel processing interrogator, which enables high sampling rates combined with highly distributed sensing (up to 96 sensors per system). The interrogation system comprises several subsystems. A broadband optical source subsystem (BOSS) and routing and interface module (RIM) send light from the interrogation system to a composite embedded FBG sensor matrix, which returns measurand-dependent wavelengths back to the interrogation system for measurement with subpicometer resolution. In particular, the returned wavelengths are channeled by the RIM to a photonic signal processing subsystem based on powerful optical chips, then passed through an optoelectronic interface to an analog post-detection electronics subsystem, digital post-detection electronics subsystem, and finally via a data interface to a computer. A range of composite structures has been fabricated with FBGs embedded. Stress tensile, bending, and dynamic strain tests were performed. The experimental work proved that the FBG sensors have a good level of accuracy in measuring the static response of the tested composite coupons (down to submicrostrain levels), the capability to detect and monitor dynamic loads, and the ability to detect defects in composites by a variety of methods including monitoring the decay time under different dynamic loading conditions. In addition to quasi-static and dynamic load monitoring, the system can capture acoustic emission events that can be a prelude to structural failure, as well as piezoactuator-induced ultrasonic Lamb-waves-based techniques as a basis for damage detection.

Moslehi, Behzad↗
NASA NTRS2016

Advanced in In Situ Inspection of Automated Fiber Placement Systems

Automated Fiber Placement (AFP) systems have been developed to help take advantage of the tailorability of composite structures in aerospace applications. AFP systems allow the repeatable placement of uncured, spool fed, preimpregnated carbon fiber tape (tows) onto substrates in desired thicknesses and orientations. This automated process can incur defects, such as overlapping tow lines, which can severely undermine the structural integrity of the part. Current defect detection and abatement methods are very labor intensive, and still mostly rely on human manual inspection. Proposed is a thermographic in situ inspection technique which monitors tow placement with an on board thermal camera using the preheated substrate as a through transmission heat source. An investigation of the concept is conducted, and preliminary laboratory results are presented. Also included will be a brief overview of other emerging technologies that tackle the same issue. Keywords: Automated Fiber Placement, Manufacturing defects, Thermography

Juarez, Peter D.↗
NASA NTRS2003

High-Performance Acousto-Ultrasonic Scan System Being Developed

Acousto-ultrasonic (AU) interrogation is a single-sided nondestructive evaluation (NDE) technique employing separated sending and receiving transducers. It is used for assessing the microstructural condition and distributed damage state of the material between the transducers. AU is complementary to more traditional NDE methods, such as ultrasonic cscan, x-ray radiography, and thermographic inspection, which tend to be used primarily for discrete flaw detection. Throughout its history, AU has been used to inspect polymer matrix composites, metal matrix composites, ceramic matrix composites, and even monolithic metallic materials. The development of a high-performance automated AU scan system for characterizing within-sample microstructural and property homogeneity is currently in a prototype stage at NASA. This year, essential AU technology was reviewed. In addition, the basic hardware and software configuration for the scanner was developed, and preliminary results with the system were described. Mechanical and environmental loads applied to composite materials can cause distributed damage (as well as discrete defects) that plays a significant role in the degradation of physical properties. Such damage includes fiber/matrix debonding (interface failure), matrix microcracking, and fiber fracture and buckling. Investigations at the NASA Glenn Research Center have shown that traditional NDE scan inspection methods such as ultrasonic c-scan, x-ray imaging, and thermographic imaging tend to be more suited to discrete defect detection rather than the characterization of accumulated distributed micro-damage in composites. Since AU is focused on assessing the distributed micro-damage state of the material in between the sending and receiving transducers, it has proven to be quite suitable for assessing the relative composite material state. One major success story at Glenn with AU measurements has been the correlation between the ultrasonic decay rate obtained during AU inspection and the mechanical modulus (stiffness) seen during fatigue experiments with silicon carbide/silicon carbide (SiC/SiC) ceramic matrix composite samples. As shown in the figure, ultrasonic decay increased as the modulus decreased for the ceramic matrix composite tensile fatigue samples. The likely microstructural reason for the decrease in modulus (and increase in ultrasonic decay) is the matrix microcracking that commonly occurs during fatigue testing of these materials. Ultrasonic decay has shown the capability to track the pattern of transverse cracking and fiber breakage in these composites.

Roth, Don J.↗
NASA NTRS2003

High-Performance Acousto-Ultrasonic Scan System Being Developed

Acousto-ultrasonic (AU) interrogation is a single-sided nondestructive evaluation (NDE) technique employing separated sending and receiving transducers. It is used for assessing the microstructural condition and distributed damage state of the material between the transducers. AU is complementary to more traditional NDE methods, such as ultrasonic cscan, x-ray radiography, and thermographic inspection, which tend to be used primarily for discrete flaw detection. Throughout its history, AU has been used to inspect polymer matrix composites, metal matrix composites, ceramic matrix composites, and even monolithic metallic materials. The development of a high-performance automated AU scan system for characterizing within-sample microstructural and property homogeneity is currently in a prototype stage at NASA. This year, essential AU technology was reviewed. In addition, the basic hardware and software configuration for the scanner was developed, and preliminary results with the system were described. Mechanical and environmental loads applied to composite materials can cause distributed damage (as well as discrete defects) that plays a significant role in the degradation of physical properties. Such damage includes fiber/matrix debonding (interface failure), matrix microcracking, and fiber fracture and buckling. Investigations at the NASA Glenn Research Center have shown that traditional NDE scan inspection methods such as ultrasonic c-scan, x-ray imaging, and thermographic imaging tend to be more suited to discrete defect detection rather than the characterization of accumulated distributed microdamage in composites. Since AU is focused on assessing the distributed microdamage state of the material in between the sending and receiving transducers, it has proven to be quite suitable for assessing the relative composite material state. One major success story at Glenn with AU measurements has been the correlation between the ultrasonic decay rate obtained during AU inspection and the mechanical modulus (stiffness) seen during fatigue experiments with silicon carbide/silicon carbide (SiC/SiC) ceramic matrix composite samples. As shown in the figure, ultrasonic decay increased as the modulus decreased for the ceramic matrix composite tensile fatigue samples. The likely microstructural reason for the decrease in modulus (and increase in ultrasonic decay) is the matrix microcracking that commonly occurs during fatigue testing of these materials. Ultrasonic decay has shown the capability to track the pattern of transverse cracking and fiber breakage in these composites.

Roth, Don J.↗
NASA NTRS2009

Very-Long-Distance Remote Hearing and Vibrometry

A proposed development of laser-based instrumentation systems would extend the art of laser Doppler vibrometry beyond the prior limits of laser-assisted remote hearing and industrial vibrometry for detecting defects in operating mechanisms. A system according to the proposal could covertly measure vibrations of objects at distances as large as thousands of kilometers and could process the measurement data to enable recognition of vibrations characteristic of specific objects of interest, thereby enabling recognition of the objects themselves. A typical system as envisioned would be placed in orbit around the Earth for use as a means of determining whether certain objects on or under the ground are of interest as potential military targets. Terrestrial versions of these instruments designed for airborne or land- or sea-based operation could be similarly useful for military or law-enforcement purposes. Prior laser-based remote-hearing systems are not capable of either covert operation or detecting signals beyond modest distances when operated at realistic laser power levels. The performances of prior systems for recognition of objects by remote vibrometry are limited by low signal-to-noise ratios and lack of filtering of optical signals returned from targets. The proposed development would overcome these limitations. A system as proposed would include a narrow-band laser as its target illuminator, a lock-in-detection receiver subsystem, and a laser-power-control subsystem that would utilize feedback of the intensity of background illumination of the target to adjust the laser power. The laser power would be set at a level high enough to enable the desired measurements but below the threshold of detectability by an imaginary typical modern photodetector located at the target and there exposed to the background illumination. The laser beam would be focused tightly on the distant target, such that the receiving optics would be exposed to only one speckle. The return signal would be extremely-narrow-band filtered (to sub-kilohertz bandwidth) in the optical domain by a whispering-gallery- mode filter so as to remove most of the background illumination. The filtered optical signal would be optically amplified. This combination of optical filtering and optical amplification would provide an optical signal that would be strong enough to be detectable but not so strong as to saturate the detector in the lock-in detection subsystem.

Maleki, Lute↗
NASA NTRS2004

"GSFC FSB Application of Perspective-Based Inspections"

The scope of work described in our proposal consisted of developing inspection standards targeted to Branch-specific types of defects (gained from analysis of Branch project defect histories), and including Branch-relevant perspectives and questions to guide defect detection. The tailored inspection guidelines were to be applied on real Branch projects with support as needed from the technology infusion team. This still accurately describes the scope of work performed. It was originally proposed that the Perspective-Based inspection standard would be applied on three projects within the Branch: GPM, JWST, and SDO. Rather than apply the proposed standard to all three, we inserted a new step, in which the standard was instead applied on a single pilot project, cFE (described above). This decision was a good match for the Branch goals since, due to the "design for reuse" nature of cFE, inspections played an even more crucial than usual role in that development process. Also, since cFE is being designed to provide general-purpose functionality, key representatives fiom our target projects were involved in inspections of cFE to provide perspectives from different missions. In this way, they could get some exposure to and the chance to provide feedback on the proposed standards before applying them on their own projects. The Branch-baselined standards will still be applied on GPM, JWST, and SDO, although outside the time frame of this funding. Finally, we originally proposed using the analysis of Branch defect sources to indicate in which phases Perspective-Based inspections could provide the best potential for future improvement, although experience on previous Branch projects suggested that our efforts would likely be focused on requirements and code inspections. In the actual work, we focused exclusively on requirements inspections, as this was the highest-priority work currently being done on our cFE pilot project.

Shell, Elaine↗
NASA NTRS1971

Ultrasonic scanning system for in-place inspection of brazed-tube joints

System detects defects of .051 cm in diameter and larger. System incorporates scanning head assembly including boot enclosed transducer, slip ring assembly, drive mechanism, and servotransmitter. Ultrasonic flaw detector, prototype recorder, and special recorder complete system.

Haralson, H. S.↗
NASA NTRS1973

Ultrasonic scanning system for in-place inspection of brazed tube joints

A miniaturized ultrasonic scanning system for nondestructive in-place, non-immersion testing of brazed joints in stainless-steel tubing is described. The system is capable of scanning brazed tube joints, with limited clearance access, in 1/4 through 5/8 inch union, tee, elbow and cross configurations. The system has the capability to detect defective conditions now associated with material density changes in addition to those which are depended upon density variations. The system includes a miniaturized scanning head assembly that fits around a tube joint and rotates the transducer around and down the joint in a continuous spiral motion. The C-scan recorder is similar in principle to conventional models except that it was specially designed to track the continuous spiral scan of the tube joint. The scanner and recorder can be operated with most commercially available ultrasonic flaw detectors.

Haynes, J. L.↗
NASA NTRS1974

A study of relationships between performance in system tests and space

Approaches for measuring the effectiveness of tests and test programs are considered, taking into account system test effectiveness, thermal-vacuum test effectiveness, and vibration test effectiveness. Methods for predicting space performance on the basis of system test effectiveness are discussed along with aspects of defect detection in thermal-vacuum tests. Questions regarding the thermal-vacuum test costs in relation to the probability of early space failures are also explored.

Timmins, A. R.↗
NASA NTRS1976

Advanced composites: Fabrication processes for selected resin matrix materials

This design note is based on present state of the art for epoxy and polyimide matrix composite fabrication technology. Boron/epoxy and polyimide and graphite/epoxy and polyimide structural parts can be successfully fabricated. Fabrication cycles for polyimide matrix composites have been shortened to near epoxy cycle times. Nondestructive testing has proven useful in detecting defects and anomalies in composite structure elements. Fabrication methods and tooling materials are discussed along with the advantages and disadvantages of different tooling materials. Types of honeycomb core, material costs and fabrication methods are shown in table form for comparison. Fabrication limits based on tooling size, pressure capabilities and various machining operations are also discussed.

Welhart, E. K.↗
NASA NTRS1982

Wire-Wrap Chatter Detector

Monitoring circuit responds to changes in resistance as little as 0.1 ohm. Has been used to detect defective wire-wrap connections during thermal and vibration tests. Defect is indicated to operator by light-emitting diode and by increase in count on a two-digit display.

Fisch, G. Z.↗