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Nondestructive Evaluation for Aerospace Composites

Nondestructive evaluation (NDE) techniques are important for enabling NASA's missions in space exploration and aeronautics. The expanded and continued use of composite materials for aerospace components and vehicles leads to a need for advanced NDE techniques capable of quantitatively characterizing damage in composites. Quantitative damage detection techniques help to ensure safety, reliability and durability of space and aeronautic vehicles. This presentation will give a broad outline of NASA's range of technical work and an overview of the NDE research performed in the Nondestructive Evaluation Sciences Branch at NASA Langley Research Center. The presentation will focus on ongoing research in the development of NDE techniques for composite materials and structures, including development of automated data processing tools to turn NDE data into quantitative location and sizing results. Composites focused NDE research in the areas of ultrasonics, thermography, X-ray computed tomography, and NDE modeling will be discussed.

Leckey, Cara↗

Applications of Advanced Nondestructive Measurement Techniques to Address Safety of Flight Issues on NASA Spacecraft

Advanced nondestructive measurement techniques are critical for ensuring the reliability and safety of NASA spacecraft. Techniques such as infrared thermography, THz imaging, X-ray computed tomography and backscatter X-ray are used to detect indications of damage in spacecraft components and structures. Additionally, sensor and measurement systems are integrated into spacecraft to provide structural health monitoring to detect damaging events that occur during flight such as debris impacts during launch and assent or from micrometeoroid and orbital debris, or excessive loading due to anomalous flight conditions. A number of examples will be provided of how these nondestructive measurement techniques have been applied to resolve safety critical inspection concerns for the Space Shuttle, International Space Station (ISS), and a variety of launch vehicles and unmanned spacecraft.

Prosser, Bill↗

An Assessment of Nondestructive Evaluation Capability for Complex Additive Manufacturing Aerospace Components

The primary focus of this work is to investigate some of the fundamental relationships between processing, mechanical testing, materials characterization, and NDE for additively manufactured (AM) components using the powder bed fusion direct melt laser sintered process. The goal is to understand the criticality of defects unique to the AM process and then how conventional nondestructive evaluation methods as well as some of the more non-traditional methods such as computed tomography, are effected by the AM material. Specific defects including cracking, porosity and partially/unfused powder will be addressed. Besides line-of-site NDE, as appropriate these inspection capabilities will be put into the context of complex AM geometries where hidden features obscure, or inhibit traditional NDE methods.

Walker, James↗

Screening and Management of Asymptomatic Renal Stones in Astronauts

Management guidelines were created to screen and manage asymptomatic renal stones in U.S. astronauts. The true risk for renal stone formation in astronauts due to the space flight environment is unknown. Proper management of this condition is crucial to mitigate health and mission risks. The NASA Flight Medicine Clinic electronic medical record and the Lifetime Surveillance of Astronaut Health databases were reviewed. An extensive review of the literature and current aeromedical standards for the monitoring and management of renal stones was also done. This work was used to develop a screening and management protocol for renal stones in astronauts that is relevant to the spaceflight operational environment. In the proposed guidelines all astronauts receive a yearly screening and post-flight renal ultrasound using a novel ultrasound protocol. The ultrasound protocol uses a combination of factors, including: size, position, shadow, twinkle and dispersion properties to confirm the presence of a renal calcification. For mission-assigned astronauts, any positive ultrasound study is followed by a low-dose renal computed tomography scan and urologic consult. Other specific guidelines were also created. A small asymptomatic renal stone within the renal collecting system may become symptomatic at any time, and therefore affect launch and flight schedules, or cause incapacitation during a mission. Astronauts in need of definitive care can be evacuated from the International Space Station, but for deep space missions evacuation is impossible. The new screening and management algorithm has been implemented and the initial round of screening ultrasounds is under way. Data from these exams will better define the incidence of renal stones in U.S. astronauts, and will be used to inform risk mitigation for both short and long duration spaceflights.

Reyes, David↗

A Biaxial-Bending Test to Observe the Growth of Interacting Delaminations in a Composite Laminate Plate

It is not easy to isolate the damage mechanisms associated with low-velocity impact in composites using traditional experiments. In this work, a new experiment is presented with the goal of generating data representative of progressive damage processes caused by low-velocity impact in composite materials. Carbon fiber reinforced polymer test specimens were indented quasi-statically such that a biaxial-bending state of deformation was achieved. As a result, a three-dimensional damage process, involving delamination and delamination-migration, was observed and documented using ultrasonic and x-ray computed tomography. Results from two different layups are presented in this paper. Delaminations occurred at up to three different interfaces and interacted with one another via transverse matrix cracks. Although this damage pattern is much less complex than that of low-velocity impact on a plate, it is more complex than that of a standard delamination coupon test and provides a way to generate delamination, matrix cracking, and delamination-migration in a controlled manner. By limiting the damage process in the experiment to three delaminations, the same damage mechanisms seen during impact could be observed but in a simplified manner. This type of data is useful in stages of model development and validation when the model is capable of simulating simple tests, but not yet capable of simulating more complex and realistic damage scenarios.

McElroy, Mark↗

Effect of Tube-Based X-Ray Microtomography Imaging on the Amino Acid and Amine Content of the Murchison CM2 Chondrite

X-ray and synchrotron X-ray micro-computed tomography (micro-CT) are increasingly being used for three dimensional reconnaissance imaging of chondrites and returned extraterrestrial material prior to detailed chemical and mineralogical analyses. Although micro-CT imaging is generally considered to be a non-destructive technique since silicate and metallic minerals in chondrites are not affected by X-ray exposures at the intensities and wavelengths typically used, there are concerns that the use of micro-CT could be detrimental to the organics in carbonaceous chondrites. We recently conducted a synchrotron micro-CT experiment on a powdered sample of the Murchison CM2 carbonaceous chondrite exposed to a monochromatic high energy (approximately 48 kiloelectronvolts) total X-ray radiation dose of approximately 1 kilogray (kGy) using the Advanced Photon Source beamline 13-BMD (13-Bending Magnet-D Beamline) at Argonne National Laboratory and found that there were no detectable changes in the amino acid abundances or enantiomeric compositions in the chondrite after exposure relative to a Murchison control sample that was not exposed. However, lower energy bremsstrahlung X-rays could interact more with amino acids and other lower molecular weight amines in meteorites. To test for this possibility, three separate micro-CT imaging experiments of the Murchison meteorite using the GE Phoenix v/tome/x s 240 kilovolt microfocus high resolution tungsten target X-ray tube instrument at the American Museum of Natural History (AMNH) were conducted and the amino acid abundances and enantiomeric compositions were determined. We also investigated the abundances of the C1-C5 amines in Murchison which were not analyzed in the first study.

Microtomography Imaging↗

Screening and Management of Asymptomatic Renal Stones in Astronauts

Management guidelines were created to screen and manage asymptomatic renal stones in U.S. astronauts. The true risk for renal stone formation in astronauts due to the space flight environment is unknown. Proper management of this condition is crucial to mitigate health and mission risks. The NASA Flight Medicine Clinic electronic medical record and the Lifetime Surveillance of Astronaut Health databases were reviewed. An extensive review of the literature and current aeromedical standards for the monitoring and management of renal stones was also done. This work was used to develop a screening and management protocol for renal stones in astronauts that is relevant to the spaceflight operational environment. In the proposed guidelines all astronauts receive a yearly screening and post-flight renal ultrasound using a novel ultrasound protocol. The ultrasound protocol uses a combination of factors, including: size, position, shadow, twinkle and dispersion properties to confirm the presence of a renal calcification. For mission-assigned astronauts, any positive ultrasound study is followed by a low-dose renal computed tomography scan and urologic consult. Other specific guidelines were also created. A small asymptomatic renal stone within the renal collecting system may become symptomatic at any time, and therefore affect launch and flight schedules, or cause incapacitation during a mission. Astronauts in need of definitive care can be evacuated from the International Space Station, but for deep space missions evacuation is impossible. The new screening and management algorithm has been implemented and the initial round of screening ultrasounds is under way. Data from these exams will better define the incidence of renal stones in U.S. astronauts, and will be used to inform risk mitigation for both short and long duration spaceflights.

Reyes, David↗

Creep/Stress Rupture Behavior of 3D Woven SiC/SiC Composites with Sylramic-iBN, Super Sylramic-iBN and Hi-Nicalon-S Fibers at 2700F in Air

To determine the influence of fiber types on creep durability, 3D SiC/SiC CMCs were fabricated with Sylramic-iBN, super Sylramic-iBN and Hi-Nicalon-S fibers and the composite specimens were then tested under isothermal tensile creep at 14820C at 69, 103 and 138 MPa for up to 300hrs in air. The failed specimens were examined by scanning electron microscopy (SEM) and computed tomography (CT) for fracture mode analysis. The creep data of these composites are compared with those of other SiC/SiC composites in the literature. The results of this study will be presented.

failure modes↗

Orion Exploration Flight Test Post-Flight Inspection and Analysis

The principal mechanism for developing orbital debris environment models, is to make observations of larger pieces of debris in the range of several centimeters and greater using radar and optical techniques. For particles that are smaller than this threshold, breakup and migration models of particles to returned surfaces in lower orbit are relied upon to quantify the flux. This reliance on models to derive spatial densities of particles that are of critical importance to spacecraft make the unique nature of the EFT-1's return surface a valuable metric. To this end detailed post-flight inspections have been performed of the returned EFT-1 backshell, and the inspections identified six candidate impact sites that were not present during the pre-flight inspections. This paper describes the post-flight analysis efforts to characterize the EFT-1 mission craters. This effort included ground based testing to understand small particle impact craters in the thermal protection material, the pre- and post-flight inspection, the crater analysis using optical, X-ray computed tomography (CT) and scanning electron microscope (SEM) techniques, and numerical simulations.

Miller, J. E.↗

Predictive Thermal Control (PTC) Technology to Enable Thermally Stable Telescopes

The Predictive Thermal Control (PTC) technology development project is a multiyear effort initiated in Fiscal Year (FY) 2017, to mature the Technology Readiness Level (TRL) of critical technologies required to enable ultra-thermally-stable telescopes for exoplanet science. During 2017/18 PTC has successfully progressed its three defined objectives: 1. Validate thermal optical performance models. 2. Derive thermal system stability specifications. 3. Demonstrate Predictive Thermal Control. by accomplishing or advancing three of its five quantifiable milestones: Milestone #1 (Complete): Created a high-fidelity STOP (Structural-Thermal-Optical-Performance) model of the1.5 meter ULE® AMTD (Advanced Mirror Technology Development)-2 mirror, including 3D CTE (Coefficient of Thermal Expansion) distribution and reflective coating, that predicts its optical performance response to steady-state and dynamic thermal gradients. Structural model was created using 3D X-Ray Computed Tomography; Milestone #2 (Complete): Derived specifications for thermal control system as a function of wavefront stability for a Vector Vortex Coronagraph; Milestone #3 (In-Process): Designed and started fabricating a predictive Thermal Control System for the AMTD-2 1.5 meter ULE® mirror that senses temperature changes and actively controls the mirror's thermal environment; Milestone #4 (In-Process): Performed preliminary STOP model validation tests of the 1.5-m ULE® mirror in a relevant thermal vacuum environment at the MSFC X-ray and Cryogenic Facility (XRCF) test facility; Milestone #5: Use validated model to perform trade studies to determine how thermo-optical performance can be optimized as a function of mirror design, material selection, mass, etc.

Stahl, H. Philip↗

Curating NASA's Past, Present, and Future Extraterrestrial Sample Collections

As codified in NASA Policy Directive 7100.10F, the Astromaterials Acquisition and Curation Office at NASA Johnson Space Center (hereafter JSC Curation) is charged with curation of all extraterrestrial material under NASA control, including future NASA missions. JSC Curation curates all or part of nine astromaterial collections in seven clean room suites: (1) Apollo Samples (1969; ISO 6-7), (2) Luna Samples (from USSR; 1972; ISO 7), (3) Antarctic Meteorites (1976; ISO 7), (4) Cosmic Dust (1981; ISO 5), (5) Microparticle Impact Collection (formerly called Space Exposed Hardware; 1985; ISO 5), (6) Genesis Solar Wind Atoms (2004; ISO 4); (7) Stardust Comet Particles (2006; ISO 5), (8) Stardust Interstellar Particles (2006; ISO 5), (9) Hayabusa Asteroid Particles (from JAXA; 2010; ISO 5). In addition to the labs that house the samples, we have installed and maintained a wide variety of facilities and infrastructure required to support the clean-rooms: more than 10 different HEPA-filtered air-handling systems, ultrapure dry gaseous nitrogen systems, an ultrapure water system (UPW) and cleaning facilities to provide clean tools and equipment for the labs. We also have sample preparation facilities for making thin sections, microtome sections, and even focused ion-beam (FIB) sections to meet the research requirements of scientists. To ensure that we are keeping the samples as pristine as possible, we routinely monitor the cleanliness of our clean rooms and infrastructure systems. This monitoring includes: daily monitoring of the quality of our UPW, weekly airborne particle counts in the labs, monthly monitoring of the stable isotope composition of the gaseous N2 system, and annual measurements of inorganic or organic contamination in processing cabinets. We track within our databases the current and ever-changing characteristics of more than 250,000 individual samples across our various collections (including the 19,141 samples on loan to 433 Principal Investigators in 24 countries). The next sample return missions that NASA will participate in are Hayabusa2 and OSIRIS-REx (Origins Spectral Interpretation Resource Identification Security - Regolith Explorer). The designs for a new state-of-the-art suite of clean rooms to house these samples at JSC have been finalized. This includes separate ISO class 5 clean rooms to house each collection, a common ISO class 7 area for general use, an ISO class 7 microtome laboratory, and a separate thin section lab. Additionally, a new cleaning facility is being designed and procedures developed that will allow for enhanced cleaning of cabinets and tools in an inorganically, organically, and biologically clean manner. We are also designing a large multi-purpose Advanced Curation laboratory that will allow us to develop the techniques necessary to fully support the Hayabusa2 and OSIRIS-REx missions, as well as future possible sample return missions (e.g., Lunar Polar Volatiles, Mars, Comet Surface). A micro-CT (micro Computed Tomography) laboratory dedicated to the study of astromaterials has come online within JSC Curation, and we plan to add additional facilities that will enable non-destructive (or minimally-destructive) analyses of astromaterials in the near future (e.g., micro-XRF (micro X-Ray Fluorescence), confocal imaging Raman Spectroscopy). These facilities will be available to: (1) develop sample handling and storage techniques for future sample return missions, (2) be utilized by PET (Positron Emission Tomography) for future sample return missions, (3) for retroactive PET-style analyses of our existing collections, and (4) for periodic assessments of the existing sample collections.

Zeigler, Ryan A.↗

Acute Effects of Simulated Space Radiation and Micro-Gravity on Cancellous Bone Loss in Mice Tibiae

Space radiation and micro-gravity are the two major obstacles impeding human exploration of Mars and beyond. Long-duration space flights expose astronauts to high doses of high linear energy transfer (LET) radiation as well as prolonged periods of skeletal disuse due to weightlessness. One important consequence of both radiation exposure and micro-gravity is acute bone loss. However, biological responses to different radiation types and combined radiation and micro-gravity environments remain unknown. Thus, the purpose of this study is to compare the acute effects of different radiation species and simulated weightlessness on bone degeneration for the purpose of developing accurate risk assessments of prolonged space flight. Mouse models were used to simulate space flight-relevant doses of different radiation types as well as weightlessness via hind-limb unloading. Three groups of mice (n 9) were irradiated with 1 Gy (Gray) H+, 1 Gy 56Fe, and 1 Gy combined H+ and 56Fe (dual ion) respectively and compared to sham irradiated (n 9) and 2 Gy 56Fe irradiated positive controls (n 6). Two groups of mice (n 9) were hind-limb unloaded for three days and then either sham irradiated or dual ion irradiated respectively, followed by subsequent hind-limb unloading for 11 days. Cancellous tissue from tibiae metaphyses were harvested 11 days post-irradiation for ex vivo micro-computed tomography analysis. Microarchitecture parameters including bone volume to total volume ratio (BVTV), trabecular thickness (Tb.Th), trabecular number (Tb.N), trabecular spacing (Tb.S), and connectivity density (Conn.D) will be quantified using a novel automated segmentation procedure developed in our lab. The anticipated results will be instrumental in developing counter-measures against micro-gravity and radiation-induced bone loss. Moreover, possible synergistic effects may provide insight into underlying mechanisms mediating biological response.

Micro-Gravity↗

Overview of the Digitization Workflow Post Image Acquisition of Apollo Lunar and Antarctic Meteorite Samples Using Agisoft Photoscan for the NASA 3D Astromaterials Virtual Samples Collection

The 3D Virtual Astromaterials Samples (3DVAS) collection is a multi-year funded project to create a digital database of sixty Apollo Lunar and Antarctic Meteorite samples following non-destructive documentation conservation protocols. After initial image processing, the photos are evaluated and processed using unique structure-from-motion photogrammetric techniques in a high performance modelling software designed to create a 3D model from 2D images: Agisoft Photoscan Pro. Agisoft Photoscan Pro uses image processing algorithms and techniques originating in computer vision to resolve 3D models for accurate and detailed visualization of a subject. The software provides a stepwise process that is tailored per model based on spatial and specular reflectance properties, for example. The process includes: photo alignment, creation of a dense point cloud, mesh, and finally texture. Photo alignment is dependent on model properties. The 3DVAS process requires a special rotation platform with calibrated photogrammetric targets, specific distance rotation protocols, and a contrasting background for alignment and scale accuracy. As a result of the photographic process, alignment will complete with two mirrored hemispheres that, in a sense, represent the 2D images overlapping to create a 3D model. Each dense point cloud is analyzed with provided statistical measures in a gradual selection process to eliminate outliers. The point cloud is reduced to include only data valuable to the final model. When a precise dense point cloud is achieved, a mesh and texture are applied. Each model is scaled with scale bar accuracies within 100 microns. Each sample has its own intimate process for modelling; there is no standard for the parameters required in the final creation of a high resolution model. By processing multiple samples, a skill is gained in practice to allow a close definition of the original sample and will result in the most detailed version of the sample shell. This process completes one-fifth of the 3DVAS protocol for providing accurate digital documentation. Each model shell is merged with X-ray Computed Tomography data to create a full volumetric sample. All 3DVAS data will be served on NASA's Astromaterials Acquisition and Curation website with an early subset of data available in 2019 and the 3D Virtual Astromaterials Samples Collection launch in 2020.

Thomas, Andi B.↗

The Geochemistry of Aubrites: Investigating Reduced Parent Bodies

The aubrites (~30 known meteorites) are a unique group of differentiated meteorites that formed on asteroids with oxygen fugacities (ƒO2) from ~2 to ~6 log units below the iron-wüstite buffer [1–2]. At these highly reduced conditions, elements deviate from the geochemical behavior exhibited at terrestrial ƒO2, forming FeO-poor silicates, Si-bearing metals, and exotic sulfides [3]. Here we examine the 3D mineralogy and the geochemistry of fourteen aubrites, including mineral major element compositions, bulk-rock compositions, and oxygen isotopic compositions to understand their formation and evolution at extreme ƒO2 conditions. While previous studies have described the petrology and 2D modal abundances of aubrites, this work investigates the 3D modal mineralogies of silicate, metal, and sulfide phases in aubrite samples, which are then com-pared to the available 2D data. We utilize X-ray computed tomography (XCT) to non-destructively analyze the distribution and abundances of mineral phases in aubrites and locate composite clasts of sulfide grains for future analysis.

Wilbur, Z. E.↗

The Apollo Sample Suite: 50 Years of Solar System Insight

The Apollo program was undoubtable a crowning achievement in human history. In addition to the obvious cultural significance, scientific results from the Apollo program had a lasting impression on a range of scientific fields, none more so that the effect the samples had on the fields of geology and cosmochemistry. The six Apollo missions collected 382 kg of rock, regolith, and core samples from geologically diverse locations on the Moon. In the nearly 50 years since the first samples were returned, there have been over 3000 different requests for samples, each yielding insights into fields as disparate as biology, medicine, astronomy, engineering, material science, and of course geology. Early studies of the Apollo samples revealed primary insights into the origin and evolution of the Moon, and of the Earth-Moon system, but the results also had implications for bodies throughout the solar system, e.g., defining crater counting rates. Over the decades, continued study of the Apollo samples by new generations of scientists using new instruments have continued to yield significant new discoveries, including the presence of endogenous water in the Moon and the possible presence of a lunar cataclysm, that in turn has contributed to new models of solar system formation and evolution. The Apollo samples have often been used as a proxy for studying other bodies like Mercury or asteroids. The Apollo samples have also directly contributed to the interpretation of remotely sensed data sets, including their use as ground truth for both Clementine and Lunar Prospector global geochemical maps. Despite the Apollo samples being a static collection, recent efforts will ensure that investigators continue to have access to new samples. For example, there was a recent solicitation for study of previously unopened Apollo samples in vacuum-sealed containers, as well as new access to samples stored frozen or in a He atmosphere. Similarly, the use of X-ray computed tomography as part of the curation process is identifying new clasts within polymict breccias that are available for study. Finally, the MoonDB project is putting all previously published lunar geochemical analyses into a searchable database, which should facilitate new investigations.

Zeigler, Ryan↗

Predictive Thermal Control (PTC) Technology to Enable Thermally Stable Telescopes: First Two Year Status

Predictive Thermal Control Technology (PTCT) development project is a multiyear effort initiated in Fiscal Year (FY) 2017, to mature the Technology Readiness Level (TRL) of critical technologies required to enable ultra-thermally-stable ultraviolet/optical/infrared (UVOIR) space telescope primary-mirror assemblies for ultra-high-contrast observations of exoplanets. Key accomplishments of 2017 to 2019 include: creating a high-fidelity STOP (Structural, Thermal, and Optical Performance) model of the AMTD-2 (Advance Mirror Technology Development) 1.5-meter Ultra-Low Expansion (ULE®) mirror (manufactured by Harris Corp) by merging 3D X-Ray computed tomography data of the ‘as-built’ mirror and coefficient of thermal expansion (CTE) data maps for each of the 18 core elements; partially validating this model by measuring the mirror’s response to bulk temperature changes and lateral thermal gradients; designed and built (with PTC partner Harris Corp) a 1.5-meter enclosure with 26 actively-control thermal zones; and defined specifications for a potential 4-meter primary mirror thermal enclosure for the Habitable Exoplanet (HabEx) Imager mission.

Astrophysics↗

Impact Damage Tolerance of Composite Laminates with Through-The-Thickness Stitches

The ability of through-the-thickness stitches to contain damage during a low-velocity impact event and increase the residual strength of stitched panels was investigated in this research. The impact response, spread of interlaminar delaminations, dent depth, surface damage, and static residual strength after impact were studied for carbon-epoxy specimens fabricated from HTS40 TohoTenax standard modulus fibers, stitched together with Vectran 1200 denier thread and infused with API 1078 resin after through-the-thickness stitching. Three different stitch patterns were used to explore the ability to arrest impact damage during and after impact. Simply supported boundary conditions were maintained during the impact testing. Non-destructive evaluations were performed using ultrasonic C-scans and X-ray computed tomography (CT) imaging to determine the shape, size, and location of delaminations. Results indicate that while the dynamic response during the impact event was almost the same for the unstitched specimens and all stitch patterns considered, the extent of delamination and the compression strength after impact varied greatly. For both the 60 J and 80 J impact energies, the delamination area was significantly less for the stitched specimens than for the unstitched specimens, but the range of delamination areas among the stitch patterns was much larger for the lower impact energy than for the greater impact energy. Similarly, while the presence of stitching influenced the compression after impact strength, the strength values for all stitch patterns were very similar. These results are a step toward quantifying the influence of through-the-thickness stitching.

Ranatunga, Vipul↗

Quadruple Simulations of Thermographic Inspections of Impacted Composites

Thermography has been shown to be a viable technique for inspection of composites. Impact damage in composites typically contains multiple overlapping delaminations at different depths. Understanding the limitations of the thermographic inspection is enhanced by performing simulations of the technique. Most simulations of composite thermographic inspections have focused on simulations of a single delamination at a fixed depth. The quadrupole method has been shown as a viable technique for rapid three-dimensional thermographic simulations of a delamination. This method is expanded to enable rapid simulation of multiple overlapping delaminations at different depths. Quadrupole simulations are compared to finite element simulations of multiple delaminations at different depths. The simulations are also compared to the thermographic measurements on impacted composites where shape and depth of the delaminations are known from x-ray computed tomography data.

Winfree, William P.↗