Elastic Property Characterization of Structrual Solids Using Contact Ultrasonics
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Method and Apparatus for Non-Destructive Evaluation of Materials
Methods and apparatus for characterizing composite materials for manufacturing quality assurance (QA), periodic inspection during the useful life, or for forensic analysis/material testing. System are provided that relate eddy-current sensor responses to the fiber layup of a composite structure, the presence of impact damage on a composite structure with or without a metal liner, volumetric stress within the composite, fiber tow density, and other NDE inspection requirements. Also provided are systems that determine electromagnetic material properties and material dimensions of composite materials from capacitive sensor inspection measurements. These properties are related to the presence of buried defects in non-conductive composite materials, moisture ingress, aging of the material due to service or environmental/thermal exposure, or changes in manufacturing quality.
Goldfine, Neil J.↗
Method and Apparatus for Non-Destructive Evaluation of Materials
Methods and apparatus for characterizing composite materials for manufacturing quality assurance (QA), periodic inspection during the useful life, or for forensic analysis/material testing. System are provided that relate eddy-current sensor responses to the fiber layup of a composite structure, the presence of impact damage on a composite structure with or without a metal liner, volumetric stress within the composite, fiber tow density, and other NDE inspection requirements. Also provided are systems that determine electromagnetic material properties and material dimensions of composite materials from capacitive sensor inspection measurements. These properties are related to the presence of buried defects in non-conductive composite materials, moisture ingress, aging of the material due to service or environmental/thermal exposure, or changes in manufacturing quality.
Goldfine, Neil J.↗
A comparison of conventional and advanced ultrasonic inspection techniques in the characterization of TMC materials
Results obtained with a conventional ultrasonic inspection technique as well as those obtained with more advanced ultrasonic NDE methods in the characterization of an 8-ply quasi-isotropic titanium matrix composite (TMC) specimen are presented. Images obtained from a conventional ultrasonic inspection of TMC material are compared with those obtained using more sophisticated ultrasonic inspection methods. It is suggested that the latter techniques are able to provide quantitative images of TMC material. They are able to reveal the same potential defect indications while simultaneously providing more quantitative information concerning the material's inherent properties. Band-limited signal loss and slope-of-attenuation images provide quantitative data on the inherent material characteristics and defects in TMC.
Holland, Mark R.↗
Some characteristics of low-cost silicon sheet
The paper discusses structural defects in low-cost silicon sheets and their effect on the electronic properties related to solar cell performance. Experimental data are presented on the influence of grain boundaries on minority carrier diffusion length, impurity defect interaction, and variable surface recombination velocity. An analytical model of the effect of grain boundaries on solar cell performance is constructed based on these results.
Koliwad, K. M.↗
Thermo-Electron Ballistic Coolers or Heaters
Electronic heat-transfer devices of a proposed type would exploit some of the quantum-wire-like, pseudo-superconducting properties of single-wall carbon nanotubes or, optionally, room-temperature-superconducting polymers (RTSPs). The devices are denoted thermo-electron ballistic (TEB) coolers or heaters because one of the properties that they exploit is the totally or nearly ballistic (dissipation or scattering free) transport of electrons. This property is observed in RTSPs and carbon nanotubes that are free of material and geometric defects, except under conditions in which oscillatory electron motions become coupled with vibrations of the nanotubes. Another relevant property is the high number density of electrons passing through carbon nanotubes -- sufficient to sustain electron current densities as large as 100 MA/square cm. The combination of ballistic motion and large current density should make it possible for TEB devices to operate at low applied potentials while pumping heat at rates several orders of magnitude greater than those of thermoelectric devices. It may also enable them to operate with efficiency close to the Carnot limit. In addition, the proposed TEB devices are expected to operate over a wider temperature range
Choi, Sang H.↗
An Electron Backscatter Diffraction (EBSD)-Based Automated Tool for Ceramic Capacitor Grain Size Analysis
Ceramic capacitors continue to be recurring problem parts for NASA, despite best efforts to screen out potential defects and failures through environmental and electrical testing and nondestructive inspection techniques such as acoustic microscopy. The physical properties of ceramic capacitors necessitates thin dielectric layers capable of withstanding significant electric fields. Any defects in those ceramic layers can result in reduced insulation resistance failure modes including short circuit failures, so the quality and consistency of the dielectric material is critical. The size of the individual ceramic grains in the dielectric material is a critical parameter. However, judging “grain size” is not so simple—in a single capacitor there can be wide variation in grain sizes observed. It is theorized that by studying the grain size distributions of “known good” and “known bad” lots of capacitors, some conclusions could be drawn that would allow us to better predict to the reliability of future lots based on grain size distributions. The initial goal of this effort was to find or develop an automated tool that could inspect a capacitor and return grain size distribution results.
Robert Hodson↗
Morphology and Luminescence Properties of Transition Metal Doped Zinc Selenide Crystals
Zinc selenide is an excellent matrix material to dope with rare-earth and transition metal to achieve mid-infrared luminescence to develop high power lasers. The luminescence, morphology and refractive index is significantly affected by the doping and defects generated due to size and valency of dopants, concentration, growth process and convection during the growth. The aim of the study is to investigate effect of point and line defects generated due to low doping of iron and chromium on the emission and morphology of the zinc selenide. Luminescence and morphological properties of large iron and chromium doped zinc selenide single crystals were studied to evaluate the effect of extremely low residual impurities and defects associated with the doping process. The emission properties following both short wavelength (i.e., ultraviolet; 350 – 370 nm) excitation and longer wavelength (i.e., near infrared; 850 – 870 nm) excitation were characterized. Luminescence emission bands were identified in both doped crystals. In addition to the primary emission bands, satellite peaks and intra-center transitions were also observed. Due to local population defects associated with the residual impurities (ppm to ppb) in the Fe-ZnSe and Cr-ZnSe crystals, peak emission wavelengths were observed to shift. Raman studies using 266 and 532 – nm excitation revealed different positions of longitudinal and transverse peaks for Fe-ZnSe and Cr-ZnSe crystals, associated with different levels of defects due to the different ion sizes. The emission bands were found to decrease in intensity due to recombination of residual impurity co-dopants and complex defects generated during growth and fabrication. Cryogenic temperature analyses revealed a very clean emission band due to freezing of some of the point and line defects. An emission band observed at 980 nm for both crystals at room temperature as well as cryogenic temperatures indicates a vibronic peak in ZnSe. The scanning electron microscopy (SEM) images of the local morphology support the conclusion that small crystallites in doped crystals are also present.
Zinc selenide↗
Quality Evaluation By Acousto-Ultrasonic Testing Of Composites
Promising nondestructive-testing method based on ultrasonic simulation of stress waves. Report reviews acousto-ultrasonic technology for nondestructive testing. Discusses principles, suggests advanced signal-analysis schemes for development, and presents potential applications. Acousto-ultrasonics applied principally to assess defects in laminated and filament-wound fiber-reinforced composite materials. Technique used to determine variations in such properties as tensile, shear, and flexural strengths and reductions in strength and toughness caused by defects. Also used to evaluate states of cure, porosities, orientation of fibers, volume fractions of fibers, bonding between fibers and matrices, and qualities of interlaminar bonds.
Vary, Alex↗
Static and dynamic properties of incommensurate smectic-A(IC) liquid crystals
The elasticity, topological defects, and hydrodynamics of the incommensurate smectic A(IC) phase liquid crystals are studied. The phase is characterized by two colinear mass density waves of incommensurate spatial frequency. The elastic free energy is formulated in terms of a displacement field and a phason field. It is found that the topological defects of the system are dislocations with a nonzero phason field and phason field components. A two-dimensional Burgers lattice for these dislocations is introduced. It is shown that the hydrodynamic modes of the phase include first- and second-sound modes whose direction-dependent velocities are identical to those in ordinary smectics.
Lubensky, T. C.↗
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.↗
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.↗
Microstructural Development of Directionally Solidified Hg(1-x)Zn(x)Se Alloys
Hg(1-x)Zn(x)Se alloys have been studied as an alternative to HgCdTe for the detection of electromagnetic radiation, because the shorter ZnSe and HgSe bonds were predicted to improve lattice stability. Previous studies showed that optical properties were stable with time and that the microhardness was higher than for HgTe based alloys. However, for this material to be commercially viable, compositional variations must be reduced, and the distribution of defects induced by the growth process must be understood. The basic structural properties of bulk materials were characterized, and dislocation etch pit densities were measured to determine whether the addition of Zn to the HgSe lattice reduced the potential for dislocation formation. Hg(0.9)Zn(0.1)Se alloys were directionally solidified using a modified Bridgman-Stockbarger method and in an applied magnetic field. Radial compositional variations were greatly reduced when solidification occurred in an applied magnetic field. The combination of a convex liquid-solid interface shape and a method for reduced wetting produced boules that were a single crystal after reaching full diameter. Observed surface features indicated ampoule wetting could be eliminated using a graphite getter. Microstructural characteristics were greatly improved over HgCdTe alloys, In six boules, a total of only one twin was observed, and no inclusions were found. A method for polishing and producing dislocation etch pits was developed for these alloys, revealing dislocation etch pit densities one to two orders of magnitude less than HgTe based alloys. A kink in the thermal profile during processing of one boule generated more dislocations than did lattice mismatch due to compositional variations. The results of this investigation indicate this alloy has improved microstructural properties and resistance to dislocation formation compared with similar II-VI alloys, and should be further investigated for the detection of electromagnetic radiation.
Cobb, S. D.↗
Automatic Review of Abstract State Machines by Meta Property Verification
A model review is a validation technique aimed at determining if a model is of sufficient quality and allows defects to be identified early in the system development, reducing the cost of fixing them. In this paper we propose a technique to perform automatic review of Abstract State Machine (ASM) formal specifications. We first detect a family of typical vulnerabilities and defects a developer can introduce during the modeling activity using the ASMs and we express such faults as the violation of meta-properties that guarantee certain quality attributes of the specification. These meta-properties are then mapped to temporal logic formulas and model checked for their violation. As a proof of concept, we also report the result of applying this ASM review process to several specifications.
Arcaini, Paolo↗
Application of superalloy powder metallurgy for aircraft engines
In the last decade, Government/Industry programs have advanced powder metallurgy-near-net-shape technology to permit the use of hot isostatic pressed (HIP) turbine disks in the commercial aircraft fleet. These disks offer a 30% savings of input weight and an 8% savings in cost compared in cast-and-wrought disks. Similar savings were demonstrated for other rotating engine components. A compressor rotor fabricated from hot-die-forged-HIP superalloy billets revealed input weight savings of 54% and cost savings of 35% compared to cast-and-wrought parts. Engine components can be produced from compositions such as Rene 95 and Astroloy by conventional casting and forging, by forging of HIP powder billets, or by direct consolidation of powder by HIP. However, each process produces differences in microstructure or introduces different defects in the parts. As a result, their mechanical properties are not necessarily identical. Acceptance methods should be developed which recognize and account for the differences.
Dreshfield, R. L.↗
Characterization of metal-polymer boundaries using Stoneley and Leaky waves
Optical and acoustooptical techniques for bonded surface inspection and interface wave detection are discussed. Interface wave propagation models based on viscous, elastic, and viscoelastic mechanical properties are reviewed. Gross boundary anomalies such as large defects and localized disbond regions were measured using conventional high frequency pulse echo and pitch catch ultratechniques. Bond durabilty is estimated by comparing detected wave attenuation versus frequency as a function of prebond surface preparation with the experimental limit obtained for perfect welded contact. Sensitivity of interface acoustic field periodicity to both residual and dc applied stress at the boundary surface is observed as well as hysteresis due to viscoelastic polymeric behavior as the applied stress is cycled.
Claus, R. O.↗
Environmental and high strain rate effects on composites for engine applications
The complex environmental and loading conditions experienced by many turbine engine components impose severe durability and damage tolerance requirements for component materials. Programs are being conducted to establish the structural performance of composite materials under anticipated engine operating environments. A description is presented of the results obtained in connection with several of these programs. A comparison of predicted and measured hygrothermal effects is considered along with hygrothermal effects on defect growth, high strain rate effects on composite mechanical properties, dynamic stress intensity factors for composites, and the indentation laws for composite impact analysis.
Chamis, C. C.↗
Monolithic Solid Oxide Fuel Cell development
The Monolithic Solid Oxide Fuel Cell (MSOFC) is an oxide-ceramic structure in which appropriate electronic and ionic conductors are fabricated in a honeycomb shape similar to a block of corrugated paperboard. These electronic and ionic conductors are arranged to provide short conduction paths to minimize resistive losses. The power density achievable with the MSOFC is expected to be about 8 kW/kg or 4 kW/L, at fuel efficienceis over 50 percent, because of small cell size and low resistive losses in the materials. The MSOFC operates in the range of 700 to 1000 C, at which temperatures rapid reform of hydrocarbon fuels is expected within the nickel-YSZ fuel channels. Tape casting and hot roll calendering are used to fabricate the MSOFC structure. The performance of the MSOFC has improved significantly during the course of development. The limitation of this system, based on materials resistance alone without interfacial resistances, is 0.093 ohm-sq cm area-specific resistance (ASR). The current typical performance of MSOFC single cells is characterized by ASRs of about 0.4 to 0.5 ohm-sq cm. With further development the ASR is expected to be reduced below 0.2 ohm-sq cm, which will result in power levels greater than 1.4 W/sq cm. The feasibility of the MSOFC concept was proven, and the performance was dramatically improved. The differences in thermal expansion coefficients and firing shrinkages among the fuel cell materials were minimized. As a result of good matching of these properties, the MSOFC structure was successfully fabricated with few defects, and the system shows excellent promise for development into a practical power source.
Myles, K. M.↗