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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS2020

Feasibility Study of SDAS Instrumentation's Ability to Identify Mobile Launcher (ML)/Crawler-Transporter (CT) Modes During Rollout Operations

The Space Launch System (SLS) and its Mobile Launcher (ML) will be transported to the launch pad via the Crawler-Transporter (CT) system. Rollout (i.e., transportation) loads produce structural loads on the integrated SLS/Orion Multi-Purpose Crew Vehicle (MPCV) launch vehicle which are of a concern with respect to fatigue. As part of the risk reduction process and in addition to the modal building block test approach that has been adopted by the SLS Program, acceleration data will be obtained during rollout for use in modal parameter estimation. There are several occurrences where the ML/CT will be transported either into the Vertical Assembly Building (VAB) or to the launch pad and back without the SLS stack as part of the Kennedy Space Center (KSC) Exploration Ground Systems (EGS) Integrated Test and Checkout (ITCO). NASA KSC EGS has instrumentation installed on both the ML and CT to record data during rollout, at the launch pad, and during liftoff. The EGS instrumentation on the ML, which includes accelerometers, is referred to as the Sensor Data Acquisition System (SDAS). The EGS instrumentation on the CT, which also includes accelerometers, is referred to as the CT Data Acquisition System (CTDAS). The forces and accelerations applied to the ML and CT during a rollout event will be higher than any of the planned building block modal tests. This can be very beneficial in helping identify nonlinear behavior in the structure. Developing modal parameters from the same test hardware in multiple boundary conditions and under multiple levels of excitation is a key step in developing a well correlated FEM. The purpose of this study was three fold. First, determine the target modes of the ML/CT in its rollout configuration. Second, determine if the test degrees of freedom (DOF) corresponding to the layout of the SDAS/CTDAS accelerometers (i.e. position and orientation) is sufficient to identify the target modes. Third, determine if the Generic Rollout Forcing Functions (GRFF's) is sufficient for identifying the ML/CT target modes accounting for variations in CT speed, modal damping, and sensor/ambient background noise levels. The finding from the first part of this study identified 28 target modes of the ML/CT rollout configuration based upon Modal Effective Mass Fractions (MEFF) and engineering judgement. The finding from the second part of this study showed that the SDAS/CTDAS accelerometers (i.e. position and orientation) are able to identify a sufficient number of the target modes to support model correlation of the ML/CT FEM. The finding from the third part of this study confirms the GRFFs sufficiently excite the ML/CT such that varying quantities of the defined target modes should be able to be extracted when utilizing an Experimental Modal Analysis (EMA) Multi-Input Multi-Output (MIMO) analysis approach. An EMA analysis approach was used because Operational Modal Analysis (OMA) tools were not available and the GRFFs were sufficiently uncorrelated. Two key findings from this third part of the study are that the CT speed does not show a significant impact on the ability to extract the modal parameters and that keeping the ambient background noise observed at each accelerometer location at or below 30 µgrms is essential to the success of this approach.

Winkel, James P.↗
NASA NTRS2012

High Resolution X-Ray Micro-CT of Ultra-Thin Wall Space Components

A high resolution micro-CT system has been assembled and is being used to provide optimal characterization for ultra-thin wall space components. The Glenn Research Center NDE Sciences Team, using this CT system, has assumed the role of inspection vendor for the Advanced Stirling Convertor (ASC) project at NASA. This article will discuss many aspects of the development of the CT scanning for this type of component, including CT system overview; inspection requirements; process development, software utilized and developed to visualize, process, and analyze results; calibration sample development; results on actual samples; correlation with optical/SEM characterization; CT modeling; and development of automatic flaw recognition software. Keywords: Nondestructive Evaluation, NDE, Computed Tomography, Imaging, X-ray, Metallic Components, Thin Wall Inspection

Roth, Don J.↗
NASA NTRS2014

Identification of New Lithic Clasts in Lunar Breccia 14305 by Micro-CT and Micro-XRF Analysis

From 1969 to 1972, Apollo astronauts collected 382 kg of rocks, soils, and core samples from six locations on the surface of the Moon. The samples were initially characterized, largely by binocular examination, in a custom-built facility at Johnson Space Center (JSC), and the samples have been curated at JSC ever since. Despite over 40 years of study, demand for samples remains high (~500 subsamples per year are allocated to scientists around the world), particularly for plutonic (e.g., anorthosites, norites, etc.) and evolved (e.g., granites, KREEP basalts) lithologies. The reason for the prolonged interest is that as new scientists and new techniques examine the samples, our understanding of how the Moon, Earth, and other inner Solar System bodies formed and evolved continues to grow. Scientists continually clamor for new samples to test their emerging hypotheses. Although all of the large Apollo samples that are igneous rocks have been classified, many Apollo samples are complex polymict breccias that have previously yielded large (cm-sized) igneous clasts. In this work we present the initial efforts to use the non-destructive techniques of micro-computed tomography (micro-CT) and micro x-ray fluorescence (micro-XRF) to identify large lithic clasts in Apollo 14 polymict breccia sample 14305. The sample in this study is 14305,483, a 150 g slab of regolith breccia 14305 measuring 10x6x2 cm (Figure 1a). The sample was scanned at the University of Texas High-Resolution X-ray CT Facility on an Xradia MicroXCT scanner. Two adjacent overlapping volumes were acquired at 49.2 micrometer resolution and stitched together, resulting in 1766 slices. Each volume was acquired at 100 kV accelerating voltage and 98 mA beam current with a 1 mm CaF2 filter, with 2161 views gathered over 360deg at 3 seconds acquisition time per view. Micro-XRF analyses were done at Washington University in St. Louis, Missouri on an EDAX Orbis PC micro-XRF instrument. Multiple scans were made at 40 kV accelerating voltage, 800 mA beam current, 30 μm beam diameter, and a beam spacing of 30-120 micrometer. The micro-CT scan of 14305,483 (Figure 2) was able to identify several large lithic clasts (approx. 1 cm) within the interior of the slab. These clasts will be exposed by band-sawing or chipping of the slab, and their composition more fully characterized by subsequent micro-XRF analysis. In addition to lithic clasts, the micro-CT scans identified numerous mineral clasts, including many FeNi metal grains, as well as the prominent fractures within the slab. The micro-XRF analyses (Figure 1b,c) of the slab surfaces revealed the bulk chemical compositions (qualitative) of the different clast types observed. In particular, by looking at the ratios of major elements (e.g. Ca:Mg:Fe), differences among the many observed clast types are readily observed. Moreover, several clasts not apparent to the naked eye were revealed in the K:Al:Si ratio map. The scans are also able to identify small grains of Zr- and P-rich minerals (not shown), which could in turn yield important age dates for the samples.

Zeigler, Ryan A.↗
NASA NTRS1990

Calibrator Blocks For Computerized Tomography (CT)

Sets of calibrator blocks developed for use with industrial computerized tomography (CT) systems. Set of blocks (or number of stacked sets of blocks) placed on object table of CT system and scanned in usual way. Blocks include holes of known size, shape, and location. Appearance of holes in output image of CT system used to verify operation of system.

Engel, H. Peter↗
NASA NTRS2017

Investigation of Carbon Fiber Architecture in Braided Composites Using X-Ray CT Inspection

During the fabrication of braided carbon fiber composite materials, process variations occur which affect the fiber architecture. Quantitative measurements of local and global fiber architecture variations are needed to determine the potential effect of process variations on mechanical properties of the cured composite. Although non-destructive inspection via X-ray CT imaging is a promising approach, difficulties in quantitative analysis of the data arise due to the similar densities of the material constituents. In an effort to gain more quantitative information about features related to fiber architecture, methods have been explored to improve the details that can be captured by X-ray CT imaging. Metal-coated fibers and thin veils are used as inserts to extract detailed information about fiber orientations and inter-ply behavior from X-ray CT images.

braided composites↗
NASA NTRSDate not supplied

In-Space Inspection Needs: Opportunities for advanced NDE tools such as x-ray CT for additively manufactured parts, in-situ resource utilization, geological applications, and more

It is now 50 years since the first human presence on the surface of the Moon and as we strive to return with women and men in the next few years, we embrace new technical challenges, goals, and innovative solutions to address 21st century objectives. These new ambitions carry fresh challenges and risks, with the field of NDE playing an increasingly more relevant role towards meeting these essential goals. In recent years, more advanced NDE tools have triggered a rapid expansion of applications for the space industry. In particular, x-ray Computed Tomography (CT) has proven to be a trusted and powerful asset for spaceflight hardware inspection, as well as applied geotechnical analysis for natural materials (e.g., rocks, soils) for NASA and across industry. However, such methods have yet to be extended to “deep space” applications such as those that are now part of the US National Space Policy Directive (SPD-1) and the accelerated push to return humans to the Moon (i.e., Artemis). For this reason, advancing these powerful Earth-based laboratory methods via new technologies, integrated computational solutions, and creative engineering approaches is directly aligned with national space policies, as well as with multiple NASA Strategic Plan priorities. The use of x-ray CT at scales as fine as a few microns or smaller can identify spacecraft part failure modes relevant to quality assurance for flight hardware and AM parts such as those recently developed for ISS. This technology could also identify valuable metallic phases within geological materials (i.e., rocks or drill cores), enabling resource-relevant triage of samples for In-Situ Resource Utilization (ISRU) and high science value sample return to Earth laboratories. There is also significant application for 3D imaging tools for medical use such as inspecting protective gear as well as bone density degradation studies which are critical in establishing a sustained presence in space. Timing for development of these tools for space use is advantageous as we prepare for new opportunities in the next few years and recognize recent commercial technology advancements which make it feasible. Moreover, as NASA strives to take full advantage of developments in AM technologies, including In-Space Manufacturing (ISM), it is widely recognized that NDE tools such as CT will play an essential role in acceptance of these parts for widespread use. New in-space 3D inspection tools with complimentary technology such as AI-based automated feature recognition (accelerated by machine learning), rapid compositional analysis, and advanced sample manipulation, would be a game-changing step toward a new class of crew-based laboratory sensors once human outposts on the Moon are established.

In-Space Non-Destructive Evaluation↗
NASA NTRS2013

Nondestructive Analysis of Astromaterials by Micro-CT and Micro-XRF Analysis for PET Examination

An integral part of any sample return mission is the initial description and classification of returned samples by the preliminary examination team (PET). The goal of the PET is to characterize and classify returned samples and make this information available to the larger research community who then conduct more in-depth studies on the samples. The PET tries to minimize the impact their work has on the sample suite, which has in the past limited the PET work to largely visual, nonquantitative measurements (e.g., optical microscopy). More modern techniques can also be utilized by a PET to nondestructively characterize astromaterials in much more rigorous way. Here we discuss our recent investigations into the applications of micro-CT and micro-XRF analyses with Apollo samples and ANSMET meteorites and assess the usefulness of these techniques in future PET. Results: The application of micro computerized tomography (micro-CT) to astromaterials is not a new concept. The technique involves scanning samples with high-energy x-rays and constructing 3-dimensional images of the density of materials within the sample. The technique can routinely measure large samples (up to approx. 2700 cu cm) with a small individual voxel size (approx. 30 cu m), and has the sensitivity to distinguish the major rock forming minerals and identify clast populations within brecciated samples. We have recently run a test sample of a terrestrial breccia with a carbonate matrix and multiple igneous clast lithologies. The test results are promising and we will soon analyze a approx. 600 g piece of Apollo sample 14321 to map out the clast population within the sample. Benchtop micro x-ray fluorescence (micro-XRF) instruments can rapidly scan large areas (approx. 100 sq cm) with a small pixel size (approx. 25 microns) and measure the (semi) quantitative composition of largely unprepared surfaces for all elements between Be and U, often with sensitivity on the order of a approx. 100 ppm. Our recent testing of meteorite and Apollo samples on micro-XRF instruments has shown that they can easily detect small zircons and phosphates (approx. 10 m), distinguish different clast lithologies within breccias, and identify different lithologies within small rock fragments (2-4 mm soil Apollo soil fragments).

Zeigler, R. A.↗
NASA NTRSDate not supplied

Enhanced Quantification of 3D Woven Composites Via Fourier Analysis and Structure Tensors Applied to CT Scans

NASA's development of advanced 3D woven carbon composites, such as HEEET and 3MDCP, represents a significant leap in materials designed to endure extreme atmospheric entry conditions. However, the internal complexity of these materials introduces a variety of structures and novel defect types. Traditional characterization methods rely on labor-intensive, manual examination of X-ray CT scans, demanding considerable time and expertise. This process, while thorough, is not sustainable for large-scale analysis and defect tracking. Addressing this critical challenge, this presentation introduces an innovative suite of automated tools and analytical techniques, pioneered by the Mars Sample Return (MSR) Earth Entry System (EES) Thermal Protection System (TPS) project. These advancements offer a more efficient and accurate approach for quantifying CT data and characterizing the defects of 3D woven composites.

Magnus Haw↗
NASA NTRSDate not supplied

Quantitative Characterization of 3D Woven Composites Via Fourier Analysis and Structure Tensors Applied to CT Scans

NASA's development of advanced 3D woven carbon composites, such as HEEET and 3MDCP, represents a significant leap in materials designed to endure extreme atmospheric entry conditions. However, the internal complexity of these materials introduces a variety of structures and novel defect types. Traditional characterization methods rely on labor-intensive, manual examination of X-ray CT scans, demanding considerable time and expertise. This process, while thorough, is not sustainable for large-scale analysis and defect tracking. Addressing this critical challenge, this presentation introduces an innovative suite of automated tools and analytical techniques, pioneered by the Mars Sample Return (MSR) Earth Entry System (EES) Thermal Protection System (TPS) project. These advancements offer a more efficient and accurate approach for quantifying CT data and characterizing the defects of 3D woven composites.

3D Woven↗
NASA NTRSDate not supplied

Characterization and Modeling of Cell Wall Imperfections in Aluminum Honeycomb Cores using X-ray CT Imaging

Honeycomb cell imperfections may significantly affect the failure of sandwich composites in core crushing and shear modes. Identification and quantification of the different types of imperfections and evaluation of their effects on the mechanical response of honeycomb cores in flatwise compression is presented. X-Ray computed tomography (CT) scans of honeycomb cores in co-cured composite sandwich panels were performed. Image analysis methods are applied to characterize and quantify core cell geometry and cell wall waviness. An approach is developed for extracting cell wall mid surface planes and waviness for constructing finite element models using shell elements. Analysis results from models with the as-manufactured imperfections are compared to results from models with idealized geometries to evaluate the effect of the as-manufactured imperfections on the initiation of cell wall buckling and subsequent core crushing.

aluminum honeycomb↗
NASA NTRSDate not supplied

Finite Element Modeling for Compression Strength Prediction of Honeycomb Cores with Geometric Imperfections Measured using X-ray CT Imaging

Aluminum honeycomb cores have been used extensively in composite sandwich panels due to having high bending rigidity while maintaining low density. During manufacturing of the aluminum honeycomb, the thin metal walls are susceptible to imperfections that deviate from an ideal honeycomb shape. Computational tools to quantify imperfections and investigate their effects on quasi-static compression and impact response can inform design criteria to construct safer and lighter launch vehicle structures. This paper presents the results of a study on finite element modeling of metallic honeycomb cores (HCC) with geometric imperfections measured using X-ray Computer Tomography (CT), to predict the compression response. Finite element (FE) models are constructed with measured imperfections with appropriate boundary conditions. It is shown that the average behavior of larger 10x11 cell models can be predicted by sampling single cell models from the larger domain. Amplification of imperfections for cells at the center of sampled specimens are mode switched from the larger out-of-plane imperfection to the mode shape of the adjacent cells resulting in strengthening of the center specimens.

aluminum honeycomb↗
NASA NTRSDate not supplied

In Situ Synchrotron Micro-CT of Microballoon-Filled RTV Silicone During Thermal Decomposition

This work investigates the thermal decomposition of microballoon-filled room-temperature-vulcanizing (RTV) silicone using time-resolved synchrotron micro-CT at the Advanced Light Source. In situ imaging of constrained and unconstrained samples captures the evolution of the internal microstructure during heating, including material expansion, microballoon and void growth, tearing, pyrolysis, shrinkage, and increasing porosity. The measurements provide new insight into the mechanisms governing RTV degradation and generate three-dimensional data for future quantitative analysis and material-response model development.

TPS↗
NASA NTRS1981

A new CT collimator for producing two simultaneous overlapping slices from one scan

A new CT collimator is developed which is capable of producing two simultaneous successive overlapping images from a single scan. The collimator represents a modification of the standard EMI 5005 collimator achieved by alternately masking one end or portions of both ends of the X-ray detectors at a 13-mm beamwidth so that a set of 540 filtered projections is obtained for each scan which can be separated into two sets of interleaved projections corresponding to views 3 mm apart. Tests have demonstrated that the quality of the images produced from these two projections almost equals the quality of those produced by the standard collimator from two separate scans. The new collimator may thus be used to achieve a speed improvement in the generation of overlapping sections as well as a reduction in X-ray dosage.

Kwoh, Y. S.↗
NASA NTRS2000

Reconstruction algorithm for polychromatic CT imaging: application to beam hardening correction

This paper presents a new reconstruction algorithm for both single- and dual-energy computed tomography (CT) imaging. By incorporating the polychromatic characteristics of the X-ray beam into the reconstruction process, the algorithm is capable of eliminating beam hardening artifacts. The single energy version of the algorithm assumes that each voxel in the scan field can be expressed as a mixture of two known substances, for example, a mixture of trabecular bone and marrow, or a mixture of fat and flesh. These assumptions are easily satisfied in a quantitative computed tomography (QCT) setting. We have compared our algorithm to three commonly used single-energy correction techniques. Experimental results show that our algorithm is much more robust and accurate. We have also shown that QCT measurements obtained using our algorithm are five times more accurate than that from current QCT systems (using calibration). The dual-energy mode does not require any prior knowledge of the object in the scan field, and can be used to estimate the attenuation coefficient function of unknown materials. We have tested the dual-energy setup to obtain an accurate estimate for the attenuation coefficient function of K2 HPO4 solution.

NASA Center ARC↗
NASA NTRS2014

Nondestructive Analysis of Apollo Samples by Micro-CT and Micro-XRF Analysis: A PET Style Examination

An integral part of any sample return mission is the initial description and classification of returned samples by the preliminary examination team (PET). The goal of a PET is to characterize and classify the returned samples, making this information available to the general research community who can then conduct more in-depth studies on the samples. A PET strives to minimize the impact their work has on the sample suite, which often limits the PET work to largely visual measurements and observations like optical microscopy. More modern techniques can also be utilized by future PET to nondestructively characterize astromaterials in a more rigorous way. Here we present our recent analyses of Apollo samples 14321 and 14305 by micro-CT and micro-XRF (respectively), assess the potential for discovery of "new" Apollo samples for scientific study, and evaluate the usefulness of these techniques in future PET efforts.

Zeigler, Ryan A.↗
NASA NTRS2015

Comprehensive Non-Destructive Conservation Documentation of Lunar Samples Using High-Resolution Image-Based 3D Reconstructions and X-Ray CT Data

Established contemporary conservation methods within the fields of Natural and Cultural Heritage encourage an interdisciplinary approach to preservation of heritage material (both tangible and intangible) that holds "Outstanding Universal Value" for our global community. NASA's lunar samples were acquired from the moon for the primary purpose of intensive scientific investigation. These samples, however, also invoke cultural significance, as evidenced by the millions of people per year that visit lunar displays in museums and heritage centers around the world. Being both scientifically and culturally significant, the lunar samples require a unique conservation approach. Government mandate dictates that NASA's Astromaterials Acquisition and Curation Office develop and maintain protocols for "documentation, preservation, preparation and distribution of samples for research, education and public outreach" for both current and future collections of astromaterials. Documentation, considered the first stage within the conservation methodology, has evolved many new techniques since curation protocols for the lunar samples were first implemented, and the development of new documentation strategies for current and future astromaterials is beneficial to keeping curation protocols up to date. We have developed and tested a comprehensive non-destructive documentation technique using high-resolution image-based 3D reconstruction and X-ray CT (XCT) data in order to create interactive 3D models of lunar samples that would ultimately be served to both researchers and the public. These data enhance preliminary scientific investigations including targeted sample requests, and also provide a new visual platform for the public to experience and interact with the lunar samples. We intend to serve these data as they are acquired on NASA's Astromaterials Acquisistion and Curation website at http://curator.jsc.nasa.gov/. Providing 3D interior and exterior documentation of astromaterial samples addresses the increasing demands for accessability to data and contemporary techniques for documentation, which can be realized for both current collections as well as future sample return missions.

Blumenfeld, E. H.↗
NASA NTRS2021

Large-Scale CT Inspection of Feed-Through EMI Filters for Space Application

A type of Feed-Through Electromagnetic Interference (EMI) Filter incorporating two discoidal (ring-shaped) capacitors was selected for use in the Europa Clipper spacecraft propulsion systems. Parts reliability specialists were aware of historical problems with the attach materials used to provide mechanical support and electrical contact within these devices, so therefore a screening was desired to ensure the longevity and ruggedness of units intended for the space environment. CT X-ray, a technology which has become more widely available thanks to the compelling depth of information it offers, was selected as the inspection method of choice.

Bescup, John C↗