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End effector on welding robot contains ultrasonic transducer detecting such flaws as tungsten inclusions and lack of penetration of weld immediately after weld made, while workpiece still mounted; weld reworked in place, if necessary. Mounted on standard arc-welding torch; same length as long gas cup with electrode.
This paper highlights the accomplishments and plans of the Federal Aviation Administration (FAA) for the development of improved nondestructive evaluation (NDE) equipment, procedures, and training. The role of NDE in aircraft safety and the need for improvement are discussed. The FAA program participants, and coordination of activities within the program and with relevant organizations outside the program are also described.
In this research, it is demonstrated that the integration of nondestructive evaluation with the finite element method (a quantitative NDE/FEM approach) can be used for analysis and behavior prediction of advanced materials, such as fiber composites, after processing and during in-service testing. First, stress, strain, and energy data were calculated by the finite element method for square plates with a 10 percent difference in the material properties between specified segments, i.e., between the center and the outside section or between two halves of the plate. This demonstrated the efficiency of the method in predicting variations in the structural behavior based on small material property differences. Then, finite element analyses and actual axial compression tests were performed on a Space Shuttle brake stator made from woven carbon-carbon composites. The material properties used in the numerical modeling of the stator were previously characterized at a large number of points on the component by quantitative NDE-procedures, i.e., ultrasonics and radiography. The results from the experimental compressive loading tests were used to verify the NDE/FEM results. Good agreement was found for most parameters.
The automated analysis of SSME injector assemblies has been investigated for the cases of LOX post surface defects and injector-baffle deterioration. Defects are isolated via 2D feature extraction from borescope and camera images; temporal-frequency transforms are then used to create a multiresolution set of feature vectors representing image contents. The potential flaws thus discriminated are then segmented and classified according to known categories. AI is applied in the form of a blackboard architecture that is controlled by a rule-based production system.
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Principal advantage of angular-power-spectrum scanning (APSS) is that, unlike x-radiography and prior ultrasonic techniques, it reveals subtle distributions of microstructural features; e.g., variations in densities of micropores or regions in which fibers and matrices are poorly bonded to each other. Potential applications include development and characterization of composite-material components of large structures, such as buildings and bridges; determination of quality and detection of damage in fiberglass hulls, surfboards, ladders, and scaffolds; and development of porous prosthetic skins and complicated "smart" materials. Superposed diffraction patterns give clues to internal structural features of ceramic composites.
A review of TQM concepts on aerospace systems is presented in a set of viewgraphs.
This paper presents an overview of the structural aspects of the design and development of a local reinforcement designed to lower the stresses in a region of the F-111C wing fitting which is prone to cracking. The stress analysis, with particular emphasis on the use of a unified constitutive model for the cyclic inelastic response of the structure, representative specimen testing, thermal analysis and full scale static testing of this design are summarized.
Using optically stimulated electron emission (OSEE), Thiokol has monitored bond surfaces in process for contamination on the Redesigned Solid Rocket Motor (RSRM). This technique provides process control information to help assure bond surface quality and repeatability prior to bonding. This paper will describe OSEE theory of operation and the instrumentation implemented at Thiokol Corporation since 1987. Data from process hardware will be presented.
In the joining of multilayer materials, and in welding, the cleanliness of the joining surface may play a large role in the quality of the resulting bond. No non-intrusive techniques are currently available for the rapid measurement of contamination on large or irregularly shaped structures prior to the joining process. An innovative technique for the measurement of contaminant levels in these structures using laser based imaging is presented. The approach uses an ultraviolet excimer laser to illuminate large and/or irregular surface areas. The UV light induces fluorescence and is scattered from the contaminants. The illuminated area is viewed by an image-intensified CCD (charge coupled device) camera interfaced to a PC-based computer. The camera measures the fluorescence and/or scattering from the contaminants for comparison with established standards. Single shot measurements of contamination levels are possible. Hence, the technique may be used for on-line NDE testing during manufacturing processes.
Computed tomography used to detect internal flaws in metal castings before machining and otherwise processing them into finished parts. Saves time and money otherwise wasted on machining and other processing of castings eventually rejected because of internal defects. Knowledge of internal defects gained by use of computed tomography also provides guidance for changes in foundry techniques, procedures, and equipment to minimize defects and reduce costs.
This work provides the information for fabricating Fabry-Perot Interferometer sensors and their performances. The Fabry-Perot Interferometer sensors developed here will be used for the detection of flaws in aircraft structures. The sequel also contains discussion of the experimental setups for the Ultrasonic technique and the Fabry-Perot Interferometer.
Techniques which have been used for finishing and quantitatively specifying surface roughness on boundary-layer-transition models are reviewed. The appearance of a surface as far as roughness is concerned can be misleading when viewed either by the eye or with the aid of a microscope. The multiple-beam interferometer and the wire shadow method provide the best simple means of obtaining quantitative measurements.
A digital video imaging system that captures the image of a single tooth of interest of a rotating gear is disclosed. The video imaging system detects the complete rotation of the gear and divide that rotation into discrete time intervals so that each tooth of interest of the gear is precisely determined when it is at a desired location that is illuminated in unison with a digital video camera so as to record a single digital image for each tooth. The digital images are available to provide instantaneous analysis of the tooth of interest, or to be stored and later provide images that yield a history that may be used to predict gear failure, such as gear fatigue. The imaging system is completely automated by a controlling program so that it may run for several days acquiring images without supervision from the user.
The portable SpectroReflectometer, an instrument developed by AZ Technology, Inc. in partnership with NASA's Kennedy Space Center is now being manufactured and sold as a cost-effective solution to the development of scientific space flight hardware. This technology originated with the efforts to determine the degradation mechanisms of the space environment on space craft materials. AZ Technology's mission is to provide high quality products and services in electro-mechanical-optical design and hardware integration, advanced thermal and optical coatings and materials, and in the development of custom hardware systems for scientific measurements.
Friction Stir Welding (FSW) has gained wide acceptance as a reliable joining process for aerospace hardware as witnessed by its recent incorporation into the Delta Launch vehicle cryotanks. This paper describes the development of nondestructive evaluation methods and techniques used to verify the FSW process for NASA's Space Shuttle.
The applicability of shearography techniques for non-destructive evaluation in two unique application areas is examined. In the first application, shearography is used to evaluate the quality of adhesive bonds holding lead tiles to the B.4T gamma ray mask for the NASA Swift program. Using a vibration excitation, the more poorly bonded tiles are readily identifiable in the shearography image. A quantitative analysis is presented that compares the shearography results with a destructive pull test measuring the force at bond failure. The second application is to evaluate the bonding between the skin and core of a honeycomb structure with a specular (mirror-like) surface. In standard shearography techniques, the object under test must have a diffuse surface to generate the speckle patterns in laser light, which are then sheared. A novel configuration using the specular surface as a mirror to image speckles from a diffuser is presented, opening up the use of shearography to a new class of objects that could not have been examined with the traditional approach. This new technique readily identifies large scale bond failures in the panel, demonstrating the validity of this approach.