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At least 1,603 records · Page 89

Mirror Attachment For Borescope

Attachment for articulated borescope provides views into small, normally inaccessible spaces. Simple small round mirror on extension arm welded to borescope head. Tilted at angle to axis of borescope head, mirror provides views sideways to borescope head. Disassembly of turbopump blades not necessary to enable fluorescent-penetrant-dye inspection. Attachment used to inspect difficult-to-reach internal parts of other assemblies. Also used for inspection with ordinary white light.

Gearhart, John F.↗

Radiographic Moire

A method for the x-ray inspection of materials making use of the Moire effect is described. The Moire effect results when two patterns are superimposed; a third pattern is produced. Any change in either of the first two patterns creates a change in the third. Moire inspection is common with visible light. This invention allows the technique to be extended to locations inaccessible to visual inspection. A first pattern of high radio contrast material is attached to or included in the sample. X-rays are projected through the sample. A second pattern is imposed at the observation point, either before or after the formation of the x-ray image. The two patterns interact to create a third, Moire, pattern. As the material is stressed the Moire pattern changes, the degree of change indicating the degree of stress.

Madaras, Eric Irvine↗

Verification of surface preparation for adhesive bonding

A survey of solid rocket booster (SRB) production operations identified potential contaminants which might adversely affect bonding operations. Lap shear tests quantified these contaminants' effects on adhesive strength. The most potent contaminants were selected for additional studies on SRB thermal protection system (TPS) bonding processes. Test panels were prepared with predetermined levels of contamination, visually inspected using white and black light, then bonded with three different TPS materials over the unremoved contamination. Bond test data showed that white and black light inspections are adequate inspection methods for TPS bonding operations. Extreme levels of contamination (higher than expected on flight hardware) had an insignificant effect on TPS bond strengths because of the apparent insensitivity of the adhesive system to contamination effects, and the comparatively weak cohesive strength of the TPS materials.

Myers, Rodney S.↗

Optoelectronic Instruments For Analysis Of Surface Defects

Family of portable optoelectronic instruments developed to facilitate inspection of surface flaws like gouges, scratches, raised metal, and dents on large metal workpieces subject to surface-finish requirements. Instrument brought to workpiece and semiautomatically makes electronic record of three-dimensional shape of flaw. Entire inspection process takes only minutes. Prototype instrument includes structured-light microscope. Concept involves projection of known pattern of light onto surface inspected. Topography of surface determined from distortion of pattern as viewed through instrument.

Collins, J. David↗

Optical Detection Of Fractures In Ceramic Diaphragms

Simple optical technique enables quick, nondestructive inspection of surfaces of ceramic diaphragms and disks for fractures and discontinuities. Involves reflecting beam of light from laser at glancing angle of about 20 degrees to 25 degrees off surface inspected and examining pattern of reflected light on suitable viewing surface as beam swept across surface. When fracture present, reflection pattern separates into two or more speckled spots. Technique applied in inspection of ceramic diaphragms bearing electronic circuits. Also useful in detection of fatigue cracks on aircraft.

Laue, Eric G.↗

Standardized Methods for Electronic Shearography

Research was conducted in development of operating procedures and standard methods to evaluate fiber reinforced composite materials, bonded or sprayed insulation, coatings, and laminated structures with MSFC electronic shearography systems. Optimal operating procedures were developed for the Pratt and Whitney Electronic Holography/Shearography Inspection System (EH/SIS) operating in shearography mode, as well as the Laser Technology, Inc. (LTI) SC-4000 and Ettemeyer SHS-94 ISTRA shearography systems. Operating practices for exciting the components being inspected were studied, including optimal methods for transient heating with heat lamps and other methods as appropriate to enhance inspection capability.

Lansing, Matthew D.↗

An OSEE Based Portable Surface Contamination Monitor

Many industrial and aerospace processes involving the joining of materials, require sufficient surface cleanliness to insure proper bonding. Processes as diverse as painting, welding, or the soldering of electronic circuits will be compromised if prior inspection and removal of surface contaminants is inadequate. As process requirements become more stringent and the number of different materials and identified contaminants increases, various instruments and techniques have been developed for improved inspection. One such technique based on the principle of Optically Stimulated Electron Emission (OSEE) has been explored for a number of years as a tool for surface contamination monitoring. Some of the benefits of OSEE are: it's non-contacting; requires little operator training; and has very high contamination sensitivity. This paper describes the development of a portable OSEE based surface contamination monitor. The instrument is suitable for both hand-held and robotic inspections with either manual or automated control of instrument operation. In addition, instrument output data is visually displayed to the operator and may be output to an external computer for archiving or analysis.

Perey, Daniel F.↗

Low-Cost Quality Control and Nondestructive Evaluation Technologies for General Aviation Structures

NASA's Advanced General Aviation Transport Experiments (AGATE) Program has as a goal to reduce the overall cost of producing private aviation aircraft while maintaining the safety of these aircraft. In order to successfully meet this goal, it is necessary to develop nondestructive inspection techniques which will facilitate the production of the materials used in these aircraft and assure the quality necessary to maintain airworthiness. This paper will discuss a particular class of general aviation materials and several nondestructive inspection techniques that have proven effective for making these inspections. Additionally, this paper will discuss the investigation and application of other commercially available quality control techniques applicable to these structures.

Cramer, K. Elliott↗

Industrial Hygiene Issues

This breakout session is a traditional conference instrument used by the NASA industrial hygiene personnel as a method to convene personnel across the Agency with common interests. This particular session focused on two key topics, training systems and automation of industrial hygiene data. During the FY 98 NASA Occupational Health Benchmarking study, the training system under development by the U.S. Environmental Protection Agency (EPA) was deemed to represent a "best business practice." The EPA has invested extensively in the development of computer based training covering a broad range of safety, health and environmental topics. Currently, five compact disks have been developed covering the topics listed: Safety, Health and Environmental Management Training for Field Inspection Activities; EPA Basic Radiation Training Safety Course; The OSHA 600 Collateral Duty Safety and Health Course; and Key program topics in environmental compliance, health and safety. Mr. Chris Johnson presented an overview of the EPA compact disk-based training system and answered questions on its deployment and use across the EPA. This training system has also recently been broadly distributed across other Federal Agencies. The EPA training system is considered "public domain" and, as such, is available to NASA at no cost in its current form. Copies of the five CD set of training programs were distributed to each NASA Center represented in the breakout session. Mr. Brisbin requested that each NASA Center review the training materials and determine whether there is interest in using the materials as it is or requesting that EPA tailor the training modules to suit NASA's training program needs. The Safety, Health and Medical Services organization at Ames Research Center has completed automation of several key program areas. Mr. Patrick Hogan, Safety Program Manager for Ames Research Center, presented a demonstration of the automated systems, which are described by the following: (1) Safety, Health and Environmental Training. This system includes an assessment of training needs for every NASA Center organization, course descriptions, schedules and automated course scheduling, and presentation of training program metrics; (2) Safety and Health Inspection Information. This system documents the findings from each facility inspection, tracks abatement status on those findings and presents metrics on each department for senior management review; (3) Safety Performance Evaluation Profile. The survey system used by NASA to evaluate employee and supervisory perceptions of safety programs is automated in this system; and (4) Documentation Tracking System. Electronic archive and retrieval of all correspondence and technical reports generated by the Safety, Health and Medical Services Office are provided by this system.

Brisbin, Steven G.↗

Thermographic Testing Using on the X-33 Space Launch Vehicle Program by BFGoodrich Aerospace

The X-33 program is a team effort sponsored by NASA, under Cooperative Agreement NCC8-115, and led by the Lockheed Martin Corporation. Team member BFGoodrich Aerospace Aerostructures Group (formerly Rohr) is responsible for design, manufacture, and integration of the Thermal Protection System (TPS) of the X-33 launch vehicle. The X-33 is a half-scale, experimental prototype of a vehicle called RLV (Reusable Launch Vehicle) or VentureStar(Trademark), an SSTO (single stage to orbit) vehicle, which is a proposed successor to the aging Space Shuttle. Thermographic testing has been employed by BFGoodrich Aerospace Aerostructures Group for a wide variety of uses in the testing of components of the X-33. Thermographic NDT (TNDT) has been used for inspecting large graphite-epoxy/aluminum honeycomb sandwich panels used on the Leeward Aeroshell structure of the X-33. And TNDT is being evaluated for use in inspecting carbon-carbon composite parts such as the nosecap and wing leading edge components. Pulsed Infrared Testing (PIRT), a special form of TNDT, is used for the routine inspection of sandwich panels made of brazed inconel honeycomb and facesheets. In the developmental and qualification testing of sub-elements of the X-33, thermography has been used to monitor 1) Arc Jet tests at NASA Ames Research Center in Mountainview, CA and NASA Johnson Space Center in Houston, TX, 2) High Temperature (wind) Tunnel Tests (HTT) at NASA Langley Research Center in Langley, VA, and 3) Hot Gas Tests at NASA Marshall Space Flight Center in Huntsville, AL.

Burleigh, Douglas↗

Study Methods to Characterize and Implement Thermography Nondestructive Evaluation (NDE)

The limits and conditions under which an infrared thermographic nondestructive evaluation can be utilized to assess the quality of aerospace hardware is demonstrated in this research effort. The primary focus of this work is on applying thermography to the inspection of advanced composite structures such as would be found in the International Space Station Instrumentation Racks, Space Shuttle Cargo Bay Doors, Bantam RP-1 tank or RSRM Nose Cone. Here, the detection of delamination, disbond, inclusion and porosity type defects are of primary interest. In addition to composites, an extensive research effort has been initiated to determine how well a thermographic evaluation can detect leaks and disbonds in pressurized metallic systems "i.e. the Space Shuttle Main Engine Nozzles". In either case, research into developing practical inspection procedures was conducted and thermographic inspections were performed on a myriad of test samples, subscale demonstration articles and "simulated" flight hardware. All test samples were fabricated as close to their respective structural counterparts as possible except with intentional defects for NDE qualification. As an added benefit of this effort to create simulated defects, methods were devised for defect fabrication that may be useful in future NDE qualification ventures.

Walker, James L.↗

Manufacturing and NDE of Large Composite Aerospace Structures at MSFC

NASA's vision for transportation to orbit calls for new vehicles built with new materials technology. The goals of this new launch system development are to improve safety, dramatically reduce cost to orbit, and improve vehicle turn around time. Planned Space Shuttle upgrades include new reusable liquid propellant boosters to replace the solid propellant boosters. These boosters are to have wings and return to the launch site for a horizontal landing on an airport runway. New single and two stages to orbit concepts are being investigated. To reduce weight and improve performance composite materials are proposed for fuel and oxidizer tanks, fuel feedlines, valve bodies, aerostructures, turbomachinery components. For large composite structures new methods of fabrication are being proposed and developed. Containment of cryogenic fuel or oxidizer requires emphases on composite material densification and chemical compatibility. Ceramic matrix and fiber composites for hot rotating turbomachinery have been developed with new fabrication processes. The new requirements on the materials for launcher components are requiring development of new manufacturing and inspection methods. This talk will examine new and proposed manufacturing methods to fabricate the revolutionary components. New NDE methods under consideration include alternative X-ray methods, X-ray laminagraphy, advanced CT, Thermography, new ultrasonic methods, and imbedded sensors. The sizes, complexity, use environment, and contamination restrictions will challenge the inspection process. In flight self-diagnosis and rapid depot inspection are also goals of the NDE development.

Whitaker, Ann↗

Defect Characterization in a Thin Walled Composite RP-1 Tank: A Case Study

A full scale thin walled composite tank, designed and fabricated for the storage of pressurized RP- I rocket fuel, was fully inspected with digital infrared thermography (IR) during assembly and prior to proof testing. The tank featured a "pill capsule" design with the equatorial bondline being overwrapped on both the inner and outer surfaces. A composite skirt was bonded to the aft dome of the tank to serve as a structural support when the tank was stood on end in service. Numerous anomalies were detected and mapped prior to proof testing, some along bondlines and some scattered throughout the acreage. After the tank was intentionally burst, coupons were cut from the regions including thermographic anomalies. These coupons were again inspected thermographically to document the growth of any indications due to proof testing. Ultrasonic inspections (UT) were also performed on the coupons for comparison to thermography. Several coupons were dissected and micrographed. Relationships between IR and UT indications and the physical nature of the dissected material are presented.

Langsing, Matthew D.↗

Thermographic Analysis of Composite Cobonds on the X-33

The methods utilized to perform an infrared thermography inspection of the bondline of structural reinforcing caps on X-33 liquid hydrogen (LH2) tank during the manufacture are described in this presentation. A total of thirty-six caps were bonded to the tank using a wet cobond process with vacuum bagging and low temperature curing. The thermal map of each bondline was acquired through the vacuum bag by applying heat to the cap and then viewing it during cool down. Poorly bonded regions, or voids, were characterized by localized hot spots in the thermal image. These regions were marked on the tank by referring to a live thermal image, then hand massaged in an attempt to remove the entrapped air. The cap was then reinspected and, if it was determined that the entrapped air could not be removed, the cap was removed and the adhesive cleaned away before it cured. Measures were then taken to better match the surface of the cap to the tank and the process repeated. After the bondline had cured sufficiently to allow vacuum bag removal, a "flash heating" thermographic Investigation was performed to verify that the cap had bonded properly to the tank. Any regions that had opened up after the preliminary inspection were marked and filled by drilling small holes in the cap and injecting resin. A final inspection was then performed to ensure the quality of the bondline.

Russell, Samual S.↗

Evolutionary Design of a Robotic Material Defect Detection System

During the post-flight inspection of SSME engines, several inaccessible regions must be disassembled to inspect for defects such as cracks, scratches, gouges, etc. An improvement to the inspection process would be the design and development of very small robots capable of penetrating these inaccessible regions and detecting the defects. The goal of this research was to utilize an evolutionary design approach for the robotic detection of these types of defects. A simulation and visualization tool was developed prior to receiving the hardware as a development test bed. A small, commercial off-the-shelf (COTS) robot was selected from several candidates as the proof of concept robot. The basic approach to detect the defects was to utilize Cadmium Sulfide (CdS) sensors to detect changes in contrast of an illuminated surface. A neural network, optimally designed utilizing a genetic algorithm, was employed to detect the presence of the defects (cracks). By utilization of the COTS robot and US sensors, the research successfully demonstrated that an evolutionarily designed neural network can detect the presence of surface defects.

Ballard, Gary↗

A Novel Approach to Rotorcraft Damage Tolerance

Damage-tolerance methodology is positioned to replace safe-life methodologies for designing rotorcraft structures. The argument for implementing a damage-tolerance method comes from the fundamental fact that rotorcraft structures typically fail by fatigue cracking. Therefore, if technology permits prediction of fatigue-crack growth in structures, a damage-tolerance method should deliver the most accurate prediction of component life. Implementing damage-tolerance (DT) into high-cycle-fatigue (HCF) components will require a shift from traditional DT methods that rely on detecting an initial flaw with nondestructive inspection (NDI) methods. The rapid accumulation of cycles in a HCF component will result in a design based on a traditional DT method that is either impractical because of frequent inspections, or because the design will be too heavy to operate efficiently. Furthermore, once a HCF component develops a detectable propagating crack, the remaining fatigue life is short, sometimes less than one flight hour, which does not leave sufficient time for inspection. Therefore, designing a HCF component will require basing the life analysis on an initial flaw that is undetectable with current NDI technology.

Forth, Scott C.↗

Damage Tolerance of Integral Structure in Rotorcraft

The rotorcraft industry has rapidly implemented integral structures into aircraft to benefit from the weight and cost advantages over traditionally riveted structure. The cost to manufacture an integral structure, where the entire component is machined from a single plate of material, is about one-fifth that of a riveted structure. Furthermore, the integral structure can weigh only one-half that of a riveted structure through optimal design of stiffening structure and part reduction. Finally, inspection and repair of damage in the field can be less costly than riveted structure. There are no rivet heads to inspect under, reducing inspection time, and damage can be removed or patched readily without altering the primary structure, reducing replacement or repair costs. In this paper, the authors will investigate the damage tolerance implications of fielding an integral structure manufactured from thick plate aluminum.

Forth, Scott C.↗

Electromagnetic Detection of Fatigue Cracks under Protruding Head Ferromagnetic Fasteners

The detection of fatigue cracks under installed fasteners has been a major goal of the aging aircraft NDE community. The Sliding Probe, Magneto-Optic Imager, Rotating Self-Nulling Probe, Low Frequency Eddy Current Array, and Eddyscan systems are among the instruments developed for this inspection. It has been verified that the detection of fatigue cracks under flush head aluminum and titanium fasteners can be accomplished with a high resolution by the above techniques. The detection of fatigue cracks under ferromagnetic and protruding head fasteners, however, has been found to be much more difficult. For the present work, the inspection for fatigue cracks under SAE 4340 Steel Hi-Lok fasteners is explored. Modifications to the Rotating Self-Nulling Eddy Current Probe System are presented which enable the detection of fatigue cracks hidden under the protruding head of the ferromagnetic fastener. Inspection results for samples with varying length EDM notches are shown, as well as a comparison between the signature from an EDM notch and an actual fatigue crack. Finite Element Modeling is used to investigate the effect of the ferromagnetic fastener on the induced eddy current distribution in order to help explain the detection characteristics of the system. This paper will also introduce a modification to the Rotating Probe System designed specifically for the detection of deeply buried flaws in multilayer conductors. The design change incorporates a giant magnetoresistive (GMR) sensor as the pickup device to improve the low frequency performance of the probe. The flaw detection capabilities of the GMR based Self- Nulling Probe are presented along with the status of the GMR based Rotating Probe System for detection of deeply buried flaws under installed fasteners.

Wincheski, Buzz↗