Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “FLAW DETECTION”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Applicability of a Conservative Margin Approach for Assessing NDE Flaw Detectability

Nondestructive Evaluation (NDE) procedures are required to detect flaws in structures with a high percentage detectability and high confidence. Conventional Probability of Detection (POD) methods are statistical in nature and require detection data from a relatively large number of flaw specimens. In many circumstances, due to the high cost and long lead time, it is impractical to build the large set of flaw specimens that is required by the conventional POD methodology. Therefore, in such situations it is desirable to have a flaw detectability estimation approach that allows for a reduced number of flaw specimens but provides a high degree of confidence in establishing the flaw detectability size. This paper presents an alternative approach called the conservative margin approach (CMA). To investigate the applicability of the CMA approach, flaw detectability sizes determined by the CMA and POD approaches have been compared on actual datasets. The results of these comparisons are presented and the applicability of the CMA approach is discussed.

Koshti, ajay M.↗
NASA NTRS2003

Flaw Detection for Composite Materials Improved by Advanced Thermal Image Reconstruction Techniques

The development of advanced composite materials for use in space and propulsion components has seen considerable growth over the past few years. In addition to improvements that have been made in material properties and processing techniques, similar growth must be seen in the development of methods for the detection of flaws, either generated in service or during manufacturing. Thermal imaging techniques have proven to be successful for the nondestructive evaluation (NDE) of composite materials, but their detection capabilities decrease as flaw depth increases. The purpose of this research is to investigate advanced thermal imaging methods and thermal image processing technologies to increase the maximum depth below surface that a flaw can be detected and improve the contrast between flawed regions and sound regions.

Martin, Richard E.↗
NASA NTRS2011

Improved Flaw Detection and Characterization with Difference Thermography

Flaw detection and characterization with thermographic techniques in graphite polymer composites is often limited by localized variations in the thermographic response. Variations in properties such as acceptable porosity, variations in fiber volume content and surface polymer thickness result in variations in the thermal response that in general cause significant variations in the initial thermal response. These variations result in a noise floor that increases the difficulty of detecting and characterizing deeper flaws. The paper investigates comparing thermographic responses taken before and after a change in state in a composite to improve the detection of subsurface flaws. A method is presented for registration of the responses before finding the difference. A significant improvement in the detectability is achieved by comparing the differences in response. Examples of changes in state due to application of a load and impact are presented.

Winfree, William P.↗
NASA NTRS2019

Assessing Reliability of NDE Flaw Detection Using Smaller Number of Demonstration Data Points

The paper provides an engineering analysis approach for assessing reliability of NDE flaw detection using smaller number of demonstration data points. It explores dependence of probability of detection (POD), probability of false positive (POF), on contrast-to-noise ratio, and net decision threshold-to-noise ratio in a simulated data; and draws some generically applicable inferences to devise the approach. ASTM nondestructive evaluation standards provide requirements on signal-to-noise ratio and/or contrast-to-noise ratio in order to provide reliable flaw detection and limit false positive calls. POD analysis of inspection test data results in an estimated flaw size, denoted by 𝑎90/95. This flaw size has 90% POD and minimum 95% confidence. POF is also estimated in the analysis. POD demonstration requires specimens with flaws of known size. In many situations, it is very expensive to produce the large number of flaws required for the POD analysis. In some situations, only real flaws can truly represent the flaws for demonstration. Real flaws of correct size and location in part configuration specimen may be difficult to produce, if not impossible. Here, an engineering analysis approach is devised using simulation to assess reliability of NDE technique when a limited number of flaws are available for demonstration. In this simulation, a technique is considered reliable, if it provides flaw detectability size equal to or better than the theoretical 𝑎90𝑡ℎ used in simulation and also provides a POF less than or equal to a chosen value. The paper uses simulated signal response versus flaw size data to devise the approach. Linear correlation is used between the signal response data and flaw size. POD software mh1823 uses generalized linear model (GLM) in POD analysis after transforming the flaw size and signal response, if needed, using logarithm. Therefore, this approach is in agreement with the linear signal correlation used in mh1823. Using the POD analysis of data, generic conditions on contrast-to-noise ratio and net decision threshold-to-noise ratio are derived for reliable flaw detection. In order to assess technique reliability using the engineering approach, signal response-to-flaw size correlation about the flaw size of concern is needed. In addition, measurement of noise is also needed. If the technique meets the above requirements, assumption of linear signal-to-flaw size correlation and conditions on noise, then the technique can be assessed using this analysis as it fits the underlying POD model used here. The approach is conservative and is designed to provide a larger flaw size compared to the POD approach. Such NDE technique assessment approach, although, not as rigorous as POD, can be cost effective if the larger flaw size can be tolerated. Typically, this is a situation for all quality control NDE inspections. Here, an NDE technique needs to be reliable and 𝑎90/95 is not estimated, but the assessed flaw size is assumed to be larger than the unknown a90 due to conservative factors or margins. Applicability of the approach for assessing reliability of flaw detection in x-ray radiography and 2D imaging in general is also explored.

Koshti, Ajay M.↗
NASA NTRS2005

Magnetoresistive Flux Focusing Eddy Current Flaw Detection

A giant magnetoresistive flux focusing eddy current device effectively detects deep flaws in thick multilayer conductive materials. The probe uses an excitation coil to induce eddy currents in conducting material perpendicularly oriented to the coil s longitudinal axis. A giant magnetoresistive (GMR) sensor, surrounded by the excitation coil, is used to detect generated fields. Between the excitation coil and GMR sensor is a highly permeable flux focusing lens which magnetically separates the GMR sensor and excitation coil and produces high flux density at the outer edge of the GMR sensor. The use of feedback inside the flux focusing lens enables complete cancellation of the leakage fields at the GMR sensor location and biasing of the GMR sensor to a location of high magnetic field sensitivity. In an alternate embodiment, a permanent magnet is positioned adjacent to the GMR sensor to accomplish the biasing. Experimental results have demonstrated identification of flaws up to 1 cm deep in aluminum alloy structures. To detect deep flaws about circular fasteners or inhomogeneities in thick multi-layer conductive materials, the device is mounted in a hand-held rotating probe assembly that is connected to a computer for system control, data acquisition, processing and storage.

Russell A Wincheski↗
NASA NTRS2005

Magnetoresistive flux focusing eddy current flaw detection

A giant magnetoresistive flux focusing eddy current device effectively detects deep flaws in thick multilayer conductive materials. The probe uses an excitation coil to induce eddy currents in conducting material perpendicularly oriented to the coil's longitudinal axis. A giant magnetoresistive (GMR) sensor, surrounded by the excitation coil, is used to detect generated fields. Between the excitation coil and GMR sensor is a highly permeable flux focusing lens which magnetically separates the GMR sensor and excitation coil and produces high flux density at the outer edge of the GMR sensor. The use of feedback inside the flux focusing lens enables complete cancellation of the leakage fields at the GMR sensor location and biasing of the GMR sensor to a location of high magnetic field sensitivity. In an alternate embodiment, a permanent magnet is positioned adjacent to the GMR sensor to accomplish the biasing. Experimental results have demonstrated identification of flaws up to 1 cm deep in aluminum alloy structures. To detect deep flaws about circular fasteners or inhomogeneities in thick multilayer conductive materials, the device is mounted in a hand-held rotating probe assembly that is connected to a computer for system control, data acquisition, processing and storage.

Wincheski, Russell A.↗
NASA NTRS2017

Reliably Detectable Flaw Size for NDE Methods that Use Calibration

Probability of detection (POD) analysis is used in assessing reliably detectable flaw size in nondestructive evaluation (NDE). MIL-HDBK-1823 and associated mh1823 POD software gives most common methods of POD analysis. In this paper, POD analysis is applied to an NDE method, such as eddy current testing, where calibration is used. NDE calibration standards have known size artificial flaws such as electro-discharge machined (EDM) notches and flat bottom hole (FBH) reflectors which are used to set instrument sensitivity for detection of real flaws. Real flaws such as cracks and crack-like flaws are desired to be detected using these NDE methods. A reliably detectable crack size is required for safe life analysis of fracture critical parts. Therefore, it is important to correlate signal responses from real flaws with signal responses form artificial flaws used in calibration process to determine reliably detectable flaw size.

Koshti, Ajay M.↗
NASA NTRS1973

Bonded panel, flaw detection standards

With optical holography or ultrasonic equipment, process prepares standards for use in detection of flaws in bonded panels. Metal-to-metal, composite-to-metal, and composite-to-composite flaw standards have been produced by this process, and all have been used and tested successfully.

Platt, R. J., Jr.↗
NASA NTRS1978

Window flaw detection by backscatter lighting

Portable fiber-optic probe detects tiny flaws in transparent materials. Probe transmits light through surface to illuminate interior of material by backscattering off its edges. Light-sensitive contact paper records scratch pattern. Technique can be used for rapid visual checks. Flexible fiber optics are safely used in explosive or flammable areas; they present no hazard of breakage or contamination in controlled environments.

Crockett, L. K.↗
DOE OSTI2026

Using 2.5D super-resolution to improve flaw detection in metal additive manufacturing parts

Industrial X-ray computed tomography (XCT) enables non-destructive inspection of additively manufactured (AM) parts, but high-resolution scanning requires long acquisition times and significant computational resources, limiting throughput in production environments. Super-resolution techniques can recover high-resolution information from low-resolution scans, but existing methods face a trade-off between 2D approaches that ignore inter-slice information and 3D methods that are computationally prohibitive for practical deployment. To address this trade-off, we propose a 2.5D deep learning-based super-resolution approach that uses seven neighbouring low-resolution slices to super-resolve the centre slice. This work evaluates the method on real XCT scans of steel AM parts, comparing reconstruction quality and flaw detection performance of 2D, 2.5D, and 3D ESRGAN-based super-resolution methods. Results demonstrate that 2.5D super-resolution significantly improves detection of small, process-induced flaws (e.g. porosity) compared to 2D methods, while avoiding the prohibitive computational burden of full 3D approaches. These findings provide initial evidence of 2.5D super-resolution as a practical, deployable solution for improving flaw detection in high-throughput industrial XCT inspection.

X-ray CT↗
NASA NTRS2015

Simulating the X-Ray Image Contrast to Set-Up Techniques with Desired Flaw Detectability

The paper provides simulation data of previous work by the author in developing a model for estimating detectability of crack-like flaws in radiography. The methodology is being developed to help in implementation of NASA Special x-ray radiography qualification, but is generically applicable to radiography. The paper describes a method for characterizing X-ray detector resolution for crack detection. Applicability of ASTM E 2737 resolution requirements to the model are also discussed. The paper describes a model for simulating the detector resolution. A computer calculator application, discussed here, also performs predicted contrast and signal-to-noise ratio calculations. Results of various simulation runs in calculating x-ray flaw size parameter and image contrast for varying input parameters such as crack depth, crack width, part thickness, x-ray angle, part-to-detector distance, part-to-source distance, source sizes, and detector sensitivity and resolution are given as 3D surfaces. These results demonstrate effect of the input parameters on the flaw size parameter and the simulated image contrast of the crack. These simulations demonstrate utility of the flaw size parameter model in setting up x-ray techniques that provide desired flaw detectability in radiography. The method is applicable to film radiography, computed radiography, and digital radiography.

Koshti, Ajay M.↗
NASA NTRS2004

Deep Flaw Detection with Giant Magnetoresistive (GMR) Based Self-Nulling Probe

In this paper a design modification to the Very-Low Frequency GMR Based Self-Nulling Probe has been presented to enable improved signal to noise ratio for deeply buried flaws. The design change consists of incorporating a feedback coil in the center of the flux focusing lens. The use of the feedback coil enables cancellation of the leakage fields in the center of the probe and biasing of the GMR sensor to a location of high magnetic field sensitivity. The effect of the feedback on the probe output was examined, and experimental results for deep flaw detection were presented. The experimental results show that the modified probe is capable of clearly identifying flaws up to 1 cm deep in aluminum alloy structures.

Wincheski, Buzz↗
NASA NTRS1990

Experimental flaw detection by scattering of plate waves

The surface displacements of elastic waves scattered from a surface-breaking crack are measured with a capacitive transducer on a 2D plate, and comparisons with theoretical predictions are reported. The noncontacting detector has a wide and flat frequency response which measures the response of a glass plate to the propagation of Rayleigh-Lamb waves. A theoretical simulation of the surface displacements is generated by multiplying experimental traces with a cosine window, and Green's function is used to compute the source function. Power spectra are also recorded from the experiment to compare the results with a finite-element model of the crack, and good agreement is reported for results in both the time and frequency domains. The crack can be detected in the far field when the spacing of the receiver locations is small, and the transducer/probe appears to be a practical flaw-detection instrument.

Spetzler, Hartmut↗
NASA NTRS1980

Surface flaw detection in structural ceramics by scanning photoacoustic spectroscopy

Laser-scanned photoacoustic spectroscopy has been used to detect tightly closed surface cracks in three structural ceramic materials: sintered silicon nitride, reaction-bonded silicon nitride, and sintered silicon carbide. It is found that the amplitude of the photoacoustic signal from the flaws is greater for the silicon nitrides than for silicon carbide, which is attributed to the lower thermal diffusivity of silicon nitride as well as differences in the grain size distribution and chemical composition. Signal amplitude, reproducibility, and signal-to-noise ratio are acceptable for effective flaw detection

Khandelwal, P. K.↗
NASA NTRS1994

Self-Nulling Eddy Current Probe for Surface and Subsurface Flaw Detection

An eddy current probe which provides a null-signal in the presence of unflawed material without the need for any balancing circuitry has been developed at NASA Langley Research Center. Such a unique capability of the probe reduces set-up time, eliminates tester configuration errors, and decreases instrumentation requirements. The probe is highly sensitive to surface breaking fatigue cracks, and shows excellent resolution for the measurement of material thickness, including material loss due to corrosion damage. The presence of flaws in the material under test causes an increase in the extremely stable and reproducible output voltage of the probe. The design of the probe and some examples illustrating its flaw detection capabilities are presented.

Wincheski, B.↗
NASA NTRSDate not supplied

NASA NDE Fracture Critical Detectable Flaw Sizes History and Methodology

NASA requires that NDE methods and inspectors demonstrate 90% Probability of Detection (POD) with 95% confidence for critical flaw sizes when inspecting fracture critical metallic components. NASA addresses the known variability of NDE inspector capability in two ways. The first, Special NDE, requires that every inspector demonstrate the required 90/95 POD, which is resource intensive. The second approach is Standard NDE for which conservative flaw sizes for different NDE methods are provided such that it is expected that most properly trained inspectors will exceed the 90/95 POD requirement. As such, individual POD demonstration testing is not required. The origin of NASA Standard NDE dates to the start of the Space Shuttle Program in the early 1970’s. In the first study to quantitatively assess NDE methods and inspectors, the performance of multiple inspectors was evaluated for different NDE methods using a large set of fatigue cracked specimens. A rudimentary POD analysis was performed to estimate the 90/95 POD flaw size for each inspector for each method. Additionally, the average and standard deviation of the 90/95 POD flaw size across the multiple inspectors was calculated to estimate the flaw size for which 95 percent of inspectors would provide the 90/95 POD capability. These estimated 90/95/95 POD flaw sizes evolved into the NASA Standard NDE flaw sizes still in use for structural analysis five decades later. The methodology for performing Standard NDE POD studies was never documented in NASA requirements. Furthermore, POD analysis methods have significantly evolved since this seminal study. Likewise, NDE methods have improved and there has been a push to reassess Standard NDE flaw sizes for existing methods, and to develop Standard NDE flaw sizes for new methods such as digital radiography. In this study, a Standard NDE POD methodology was developed and baselined using the historical data. This reanalysis of the historical data identified several deficiencies in the original test plan as well as an overall lack of conservatism in the estimated 90/95/95 POD flaw sizes. The results of this historical review and the new methodology are being incorporated into an update of NASA NDE POD requirements.

Nondestructive Evaluation↗