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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Analysis of Eddy Current Capabilities for the Detection of Outer Diameter Stress Corrosion Cracking in Small Bore Metallic Structures

The use of eddy current techniques for the detection of outer diameter damage in tubing and many complex aerospace structures often requires the use of an inner diameter probe due to a lack of access to the outside of the part. In small bore structures the probe size and orientation are constrained by the inner diameter of the part, complicating the optimization of the inspection technique. Detection of flaws through a significant remaining wall thickness becomes limited not only by the standard depth of penetration, but also geometrical aspects of the probe. Recently, an orthogonal eddy current probe was developed for detection of such flaws in Space Shuttle Primary Reaction Control System (PRCS) Thrusters. In this case, the detection of deeply buried stress corrosion cracking by an inner diameter eddy current probe was sought. Probe optimization was performed based upon the limiting spatial dimensions, flaw orientation, and required detection sensitivity. Analysis of the probe/flaw interaction was performed through the use of finite and boundary element modeling techniques. Experimental data for the flaw detection capabilities, including a probability of detection study, will be presented along with the simulation data. The results of this work have led to the successful deployment of an inspection system for the detection of stress corrosion cracking in Space Shuttle Primary Reaction Control System (PRCS) Thrusters.

Wincheski, Buzz↗
NASA NTRS1982

Dip-Coating Fabrication of Solar Cells

Inexpensive silicon solar cells made by simple dip technique. Cooling shoes direct flow of helium on graphite-coated ceramic substrate to solidify film of liquid silicon on graphite surface as substrate is withdrawn from molten silicon. After heaters control cooling of film and substrate to prevent cracking. Gas jets exit at points about 10 mm from substrate surfaces and 6 to 10 mm above melt surface.

Koepke, B.↗
NASA NTRS1998

Degradation of Teflon(tm) FEP Following Charged Particle Radiation and Rapid Thermal Cycling

During the Second Servicing Mission (SM2) of the Hubble Space Telescope (HST) severe degradation was observed on the outer layer of the thermal control blankets. Astronaut observations and photographs revealed large cracks in the metallized Teflon FEP (fluorinated ethylene propylene), the outer layer of the multi-layer insulation (MLI), in many locations around the telescope. In an effort to understand what elements of the space environment might cause such damage, pristine Teflon' FEP was tested for durability to radiation and thermal cycling. Specimens were subjected to electron and proton fluences comparable to those experienced by HST and were subsequently thermal cycled in a custom-built rapid thermal cycle chamber. Tensile tests of the specimens showed that radiation followed by thermal cycling significantly reduced the ultimate strength and elongation of Teflon FEP.

Townsend, Jacqueline A.↗
NASA NTRS1998

Degradation of Teflon(tm) FEP Following Charged Particle Radiation and Rapid Thermal Cycling

During the Second Servicing Mission (SM2) of the Hubble Space Telescope (HST) severe degradation was observed on the outer layer of the thermal control blankets. Astronaut observations and photographs revealed large cracks in the metallized Teflon' FEP (fluorinated ethylene propylene), the outer layer of the multi-layer insulation (MLI), in many locations around the telescope. In an effort to understand what elements of the space environment might cause such damage, pristine Teflon(registered trademark) FEP was tested for durability to radiation and thermal cycling. Specimens were subjected to electron and proton fluences comparable to those experienced by HST and were subsequently thermal cycled in a custom-built rapid thermal cycle chamber. Tensile tests of the specimens showed that radiation followed by thermal cycling significantly reduced the ultimate strength and elongation of Teflon(registered trademark) FEP.

Townsend, Jacqueline A.↗
NASA NTRS1998

Degradation of Teflon(tm) FEP Following Charged Particle Radiation and Rapid Thermal Cycling

During the Second Servicing Mission (SM2) of the Hubble Space Telescope (HST) severe degradation was observed on the outer layer of the thermal control blankets. Astronaut observations and photographs revealed large cracks in the metallized Teflon(R) FEP (fluorinated ethylene propylene), the outer layer of the multi-layer insulation (MLI), in many locations around the telescope. In an effort to understand what elements of the space environment might cause such damage, pristine Teflon(R) FEP was tested for durability to radiation and thermal cycling. Specimens were subjected to electron and proton fluences comparable to those experienced by HST and were subsequently thermal cycled in a custom-built rapid thermal cycle chamber. Tensile tests of the specimens showed that radiation followed by thermal cycling significantly reduced the ultimate strength and elongation of Teflon(R) FEP.

Townsend, Jacqueline↗
NASA NTRS1999

Degradation of Teflon(trademark) FEP Following Charged Particle Radiation and Rapid Thermal Cycling

During the Second Servicing Mission (SM2) of the Hubble Space Telescope (HST) severe degradation was observed on the outer layer of the thermal control blankets. Astronaut observations and photographs revealed large cracks in the metallized Teflon(trademark) FEP (fluorinated ethylene propylene), the outer layer of the multi-layer insulation (MLI), in many locations around the telescope. In an effort to understand what elements of the space environment might cause such damage, pristine Teflon(trademark) FEP was tested for durability to radiation and thermal cycling. Specimens were subjected to electron and proton fluences comparable to those experienced by HST and were subsequently thermal cycled in a custom-built rapid thermal cycle chamber. Tensile tests of the specimens showed that radiation followed by thermal cycling significantly reduced the ultimate strength and elongation of Teflon(trademark) FEP.

Townsend, Jacqueline↗
NASA NTRS2006

Oxidation Microstructure Studies of Reinforced Carbon/Carbon

Laboratory oxidation studies of reinforced carbon/carbon (RCC) are discussed with particular emphasis on the resulting microstructures. This study involves laboratory furnace (500-1500 C deg) and arc-jet exposures (1538 C deg) on various forms of RCC. RCC without oxidation protection oxidized at 800 and 1100 C deg exhibits pointed and reduced diameter fibers, due to preferential attack along the fiber edges. RCC with a SiC conversion coating exhibits limited attack of the carbon substrate at 500, 700 and 1500 C deg. However samples oxidized at 900, 1100, and 1300 C deg show small oxidation cavities at the SiC/carbon interface below through-thickness cracks in the SiC coating. These cavities have rough edges with denuded fibers and can be easily distinguished from cavities created in processing. Arc-jet tests at 1538 C deg show limited oxidation attack when the SiC coating and glass sealants are intact. When the SiC/sealant protection system is damaged, attack is extensive and proceeds through matrix cracks, creating denuded fibers on the edges of the cracks. Even at 1538 C deg, where diffusion control dominates, attack is non-uniform with fiber edges oxidizing in preference to the bulk fiber and matrix.

Jacobson, Nathan S.↗
NASA NTRS2008

Assessment of Proper Bonding Methods and Mechanical Characterization FPGA CQFPs

This presentation discusses fractured leads on field-programmable gate array (FPGA) during flight vibration. Actions taken to determine root cause and resolution of the failure include finite element analysis (FEA) and vibration testing and scanning electron microscopy (with X-ray microanalysis) and energy dispersive spectrometry (SEM/EDS) failure assessment. Bonding methods for surface mount parts is assessed, including critical analysis and assessment of random fatigue damage. Regarding ceramic quad flat pack (CQFP) lead fracture, after disassembling the attitude control electronics (ACE) configuration, photographs showed six leads cracked on FPGA RTSX72SU-1 CQ208B package located on the RWIC card. An identical package (FPGA RTSX32SU-1 CQ208B) mounted on the RWIC did not results in cracked pins due to vibration. FPGA lead failure theories include workmanship issues in the lead-forming, material defect in the leads of the FPGA packages, and the insecure mounting of the board in the card guides, among other theories. Studies were conducted using simple calculations to determine the response and fatigue life of the package. Shorter packages exhibited more response when loaded by out-of-plane displacement of PCB while taller packages exhibit more response when loaded by in-plane acceleration of PCB. Additionally, under-fill did not contribute to reducing stress in leads due to out-of-plane PCB loading or from component twisting, as much as corner bonding. The combination of corner bond and under-fill is best to address mechanical and thermal S/C environment. Test results of bonded parts showed reduced (dampened) amplitude and slightly shifted peaks at the un-bonded natural frequency and an additional response at the bonded frequency. Stress due to PCBB out-of-plane loading was decreased on in the corners when only a corner bond was used. Future work may address CQFP fatigue assessment, including the investigation of discrepancy in predicted fatigue damage, as well as comparing fatigue life and fatigue damage cycle ration computed using FEA and Miner's rule to results from a fatigue assessment software program.

Davis, Milton C.↗
NASA NTRS2008

Engineering Models Ease and Speed Prototyping

NASA astronauts plan to return to the Moon as early as 2015 and establish a lunar base, from which 6-month flights to Mars would be launched by 2030. Essential to this plan is the Ares launch vehicle, NASA s next-generation spacecraft that will, in various iterations, be responsible for transporting all equipment and personnel to the Moon, Mars, and beyond for the foreseeable future. The Ares launch vehicle is powered by the J-2X propulsion system, with what will be the world s largest rocket nozzles. One of the conditions that engineers carefully consider in designing rocket nozzles particularly large ones is called separation phenomenon, which occurs when outside ambient air is sucked into the nozzle rim by the relatively low pressures of rapidly expanding exhaust gasses. This separation of exhaust gasses from the side-wall imparts large asymmetric transverse loads on the nozzle, deforming the shape and thus perturbing exhaust flow to cause even greater separation. The resulting interaction can potentially crack the nozzle or break actuator arms that control thrust direction. Side-wall loads are extremely difficult to measure directly, and, until now, techniques were not available for accurately predicting the magnitude and frequency of the loads. NASA researchers studied separation phenomenon in scale-model rocket nozzles, seeking to use measured vibration on these nozzle replicas to calculate the unknown force causing the vibrations. Key to this approach was the creation of a computer model accurately representing the nozzle as well as the test cell.

Source record↗
NASA NTRSDate not supplied

Certifying Acoustic Emission for the Crack Inspection of Integrated Pressure Components

To address the limitations of other nondestructive evaluation (NDE) methods on integrated components due to access constraints, a novel Acoustic Emission (AE) pressure vessel health test was developed in accordance with ASME BPVC.V Article 12. This test was then validated using notched Ti-6Al-4V panels taken to a stress level equivalent to 1.1 times the Maximum Allowable Working Pressure (MAWP) of a flight pressure vessel. The assessment involved utilizing JSC small sample Probability of Detection (POD) calculations, which represents the initial step towards obtaining flight certification for an NDE technique. A robust filtering technique that specifically identifies crack growth was formulated with the assistance of industry partners. This detection method exhibited superior detection ability compared to other NDE methods or microscopy. Within industry, the presence of a group of triangulated energetic crack-like indications typically leads to supplemental inspection or the failure of a tank. The experimental results confirm that this approach, commonly applied to more robust tanks, can be viably extended to integrated aerospace pressure components in scenarios where components can be subjected to pressures up to 1.1 times the MAWP. The testing process encountered delays due to sensor delivery and panel fabrication. Thus far, samples with crack initiators have shown energy levels 10 times higher than blunted controls. This suggests a trend where high individual and total cluster energy could be employed as acceptance criteria. Moreover, the cumulative energy of clusters might serve as a foundation for estimating crack sizes; however, this aspect requires further assessment and localized supplemental inspections are preferred.

certifying↗
NASA NTRS2019

Cracking Problems in Low-Voltage Chip Ceramic Capacitors

Cracking remains the major reason of failures in multilayer ceramic capacitors (MLCCs) used in in space electronics. Due to a tight quality control of space-grade components, the probability that as manufactured capacitors have cracks is relatively low, and cracking is often occurs during assembly, handling and the following testing of the systems. Majority of capacitors with cracks are revealed during the integration and testing period, but although extremely rarely, defective parts remain undetected and result in failures during the mission. This situation is aggravated by manual soldering and rework that are often used during low volume production of circuit boards for space. Although failures of MLCCs are often attributed to the post-manufacturing stresses, in many cases they are due to a combination of certain deviations in the manufacturing processes that result in hidden defects in the parts and excessive stresses during assembly and use. This report gives an overview of design, manufacturing and testing processes of MLCCs focusing on elements related to cracking problems. The existing and new screening and qualification procedures and techniques are briefly described and assessed by their effectiveness in revealing cracks. The capability of different test methods to simulate stresses resulting in cracking, mechanisms of failures in capacitors with cracks, and possible methods of selecting the most robust to manual soldering stresses capacitors are discussed.

testing↗
NASA NTRS1973

Sensitivity and comparison evaluation of Saturn 5 liquid penetrants

Results of a sensitivity and comparison evaluation performed on six liquid penetrants that were used on the Saturn 5 vehicle and other space hardware to detect surface discontinuities are described. The relationship between penetrant materials and crack definition capabilities, the optimum penetrant materials evaluation method, and the optimum measurement methods for crack dimensions were investigated. A unique method of precise developer thickness control was envolved, utilizing clear radiographic film and a densitometer. The method of evaluation included five aluminum alloy, 2219-T87, specimens that were heated and then quenched in cold water to produce cracks. The six penetrants were then applied, one at a time, and the crack indications were counted and recorded for each penetrant for comparison purposes. Measurements were made by determining the visual crack indications per linear inch and then sectioning the specimens for a metallographic count of the cracks present. This method provided a numerical approach for assigning a sensitivity index number to the penetrants. Of the six penetrants evaluated, two were not satisfactory (one was not sufficiently sensitive and the other was to sensitive, giving false indications). The other four were satisfactory with approximately the same sensitivity in the range of 78 to 80.5 percent of total cracks detected.

Jones, G. H.↗
NASA NTRS1991

Elevated temperature mechanical behavior of monolithic and SiC whisker-reinforced silicon nitrides

The mechanical behavior of a 30 volume percent SiC whisker reinforced silicon nitride and a similar monolithic silicon nitride were measured at several temperatures. Measurements included strength, fracture toughness, crack growth resistance, dynamic fatigue susceptibility, post oxidation strength, and creep rate. Strength controlling defects were determined with fractographic analysis. The addition of SiC whiskers to silicon nitride did not substantially improve the strength, fracture toughness, or crack growth resistance. However, the fatigue resistance, post oxidation strength, and creep resistance were diminished by the whisker addition.

Salem, Jonathan A.↗
NASA NTRS1983

A critical study of the crack closure effect on near-threshold fatigue crack growth

Crack closure in the near-crack-tip region has been considered to be an important contribution to the development of a crack-growth threshold for macroscopic cracks. Recent analytical work, however, has suggested that closure well back of the tip may be the controlling factor. In order to check on this possibility, material has been machined away far behind the crack tip in order to eliminate long-range closure. Removal of this material did not eliminate the threshold, but did lower the threshold level by approximately 10 percent for tests conducted on 6.3 mm-thick X7090-T6 powder metallurgy aluminum alloy.

Minakawa, K.↗
NASA NTRS1974

Space Shuttle Orbiter Fracture Control Plan

The criteria are presented for preventing space shuttle structural failure associated with crack initiation or propagation during fabrication, test, handling, and the operational life of the vehicle. The criteria discussed include: engineering responsibilities, assurance management, production, operation and test, procurement, critical parts selection, design, and structural analysis.

Fracture control↗
NASA NTRS1997

The Development of Engineering Tomography for Monolithic and Composite Materials and Components

The research accomplishments under this grant were very extensive in the areas of the development of engineering tomography for monolithic and composite materials and components. Computed tomography was used on graphite composite pins and bushings to find porosity, cracks, and delaminations. It supported the following two programs: Reusable Launch Vehicle (RLV) and Southern Research institute (SRI). Did research using CT and radiography on Nickel based Superalloy dogbones and found density variations and gas shrinkage porosity. Did extensive radiography and CT of PMC composite flywheels and found delamination and non-uniform fiber distribution. This grant supported the Attitude Control Energy Storage Experiment (ACESE) program. Found broken fibers and cracks of outer stainless steel fibers using both radiographic and CT techniques on Pratt and Whitney fuel lines; Supported the Pratt & Whitney and Aging Aircraft engines program. Grant research helped identify and corroborate thickness variations and density differences in a silicon nitride "ROTH" tube using computed tomography.

Hemann, John↗
NASA NTRS1992

Mixed-mode fracture in unidirectional graphite epoxy composite laminates with central notch

Mixed-mode matrix fracture in central notched off-axis unidirectional composite laminates was investigated. A limited number of unidirectional tensile type specimens with a central, horizontal, notch were tested. Crack initiation and propagation were examined under various local stress fields that were controlled by fiber orientations. The tested specimens were simulated using a two dimensional finite element method with constant strain loading. The strain energy release rates along the crack were evaluated via crack closure technique. The variation of critical strain energy rates with off-axis angle was studied. The results from single (one-sided) and double (two-sided) crack simulations were presented and compared.

Binienda, Wieslaw K.↗
NASA NTRS1993

External stress-corrosion cracking of a 1.22-m-diameter type 316 stainless steel air valve

An investigation was conducted to determine the cause of the failure of a massive AISI Type 316 stainless steel valve which controlled combustion air to a jet engine test facility. Several through-the-wall cracks were present near welded joints in the valve skirt. The valve had been in outdoor service for 18 years. Samples were taken in the cracked regions for metallographic and chemical analyses. Insulating material and sources of water mist in the vicinity of the failed valve were analyzed for chlorides. A scanning electron microscope was used to determine whether foreign elements were present in a crack. On the basis of the information generated, the failure was characterized as external stress-corrosion cracking. The cracking resulted from a combination of residual tensile stress from welding and the presence of aqueous chlorides. Recommended countermeasures are included.

Moore, Thomas J.↗