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NASA NDE WORKING GROUPNEWSLETTER
August 1996 Quarterly Newsletter VOL. 4, NO. 3
WWW URL address: http://ndeaa.jpl.nasa.gov/
CODE Q NDE PROGRAM MANAGERMESSAGEEdward R. Generazio, LaRC, [email protected] Members: This fiscal year we will use adramatically different process for initiating tasksfor FY97. Details of the process will beforthcoming in early August. Let's all lookforward to having a good year and meeting ourFY97 milestones. This quarter, we successfullyadvocated the early start of three NDE tasks whileproviding additional substantial funds forupgrading our NDE equipment infrastructure. Wealso are planning a small growth in the NDEprogram over the next 5 years. We will need tomaintain, enhance, and report on our highlyproductive activities.
NNWG NEWSLETTER IS BECOMINGELECTRONICThis is the last hardcopy issue of the NNWGNewsletter. Due to the high cost, a decision wasmade to change our Newsletter to an electronicformat only. The new version of the Newsletterwill have enhanced technical details and will beaccessible to NASA only and will serve as aninternal NASA NDE Working Group forum ofcommunication and archival. A publically availableversion will be accessible at the LaRC Websiteaddress: http://zeta.larc.nasa.gov/docs/nesb.html
NNWG CHAIR MESSAGEGeorge Y. Baaklini 216-433-6016A Telecon was called to order by the NNWGChair George Baaklini at 2:05 p.m. EST, July 18,1996, and involved 14 attendees, including:Yoseph Bar-Cohen, JPL; Jim Chern and BradParker, GSFC; John Larson and Rick Russell,KSC; Linda Clark Sam Russell and BobNeuschaefer, MSFC; Bill St. Cyr, SSC; JohnSegreto, ARC; Marie Havican, JSC; Ed Generazio,LaRC; and George Baaklini and Don Roth, LeRC. The following topics were discussed:
CONTENTS PAGE NO.
CODE Q NDE PROGRAM MANAGER MESSAGE .......1
NNWG NEWSLETTER IS BECOMING ELECTRONICAND NASA-ONLY .............................................................1
NNWG CHAIR MESSAGE................................................1
NNWG HIGHLIGHTS.......................................................2
ORBITER NDE SUB-COMMITTEE (ONSC) ..................2
NNWG PERSONNEL NEWS ............................................3
NASA CENTERS NEWS....................................................3
JPL ...................................................................................3JSC ...................................................................................6KSC..................................................................................6LARC................................................................................7LERC ..............................................................................10MSFC .............................................................................10
COMING EVENTS ..........................................................11
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Status of the FY’97 Budget Planning Exercise(BPE) call - Ed Generazio has already funded 3additional NDE tasks (2 from KSC and one fromMSFC) from FY96 resources. He has identifiedremaining tasks as possible FY’97 new starts. Some of these tasks need further supporthighlighting “Flight critical", "Mission critical","substantial cofunding", and "leveraging industryinput and interests". Next year, according to Ed,we will have no popcalls the way we know it. Instead, we will have tasks worked and identifiedwithin the group. The NDE thrusts will be onHuman Space Flight and Aeronautics.Costings of FY96 programs - RTOPs should becosted at the level of at least 75% of the FY96fund by Sept. 30th with 25% carry over to be spentin early FY97. Ed is planning to improve theNDE budget via slow growth through to FY’99.NDE infrastructure Support - The infrastructuresupport is expected to reach the Centers soon. The procurement should be costed in two monthsfrom receipt of funds. To assist in making this asmooth transition, each Center was asked tosubmit to Ed the name and phone number of theCenter’s Administration Management Specialists. All the names from each center that were receivedby LeRC were forwarded to Ed by COB 7-19-1996.Decision on the future of the Newsletters - Edstated that in FY’97 the Newsletter in thehardcopy format will be a thing of the past. Thenew way of communicating news in FY97 will beelectronic. Ed will initiate the input and it will bemodified/added-on by each of the working groupmembers. A publically accessible version will beavailable at the LaRC Website.NNWG workshop at JPL - The official date forthe 4th NNWG workshop was set for Feb. 25 and26, and on the 27th there will be a tour of JPL anda Vendors' Exhibit (not part of the NNWGWorkshop agenda).Noinations for a Chair and Vice Chair for theCode Q committee - Bob Neuschaefer has askedthe members of NNWG to nominate others or selffor these two positions by August 1st, hoping tohave the votes in by August 14, and to reportresults by August 15.
Focal point for ISO 9000 - Marie Havican wasappointed to serve as the focal point, whereYoseph Bar-Cohen and John Larson are going tohelp in establishing and expanding on the NPDplan for NDE.Jim Chern's proposal on "NDE PersonnelQualification and Certification DevelopmentProcess” - Jim Chern’s proposal was e-mailed toall the members prior to the Telecon, and Jim andEd are expecting a feedback from all of ushopefully by the next Telecon as to whether weshould support this activity or not.Orbiter Sub-Committee - briefing by RickRussell was scheduled for next Telecon, sometimein Sept.
NNWG HIGHLIGHTSRTOP IS NOW BUDGET PLANNINGEXERCISE (BPE) - NASA HQ has a new processfor RTOPs, now called BPEs (Business PlanExercise). A large package was sent out to all theCenters to provide a guide. In parallel, EdGenerazio sent a package to each of the membersof NNWG specifically addressing the BPE call forNDE proposals. The proposals are due by to thedelegated manager by August 12, 1996 and theyrepresent a new way for soliciting Code Q requestfor proposals with emphasis on deliverables thatdirectly support NASA’s missions.
ORBITER NDE SUB-COMMITTEE(ONSC)Rick Russell, 407-861-4168 [email protected] ORBITER NDE SUB-COMMITTEE(ONSC) HELD A TELECON ON JUNE 17,1996 - A progress report on the consolidation of standards was given by Chris Davis, NASA KSC. All members were encouraged to continuesupporting this effort. The topic of transportationof standards was also discussed.
The group then welcomed new participants fromRockwell Canoga Park who gave presentations ontheir use of Real Time Radiography and thedevelopment of X-ray film digitization. The teammembers from KSC were especially appreciative of
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this information since they are interested inobtaining a digitization system.
NNWG PERSONNEL NEWS
Don Roth, winner of theR&D 100 award.
Congratulations to Don J. Roth, LaRC forwining the R&D100 Award - The NASA NDEWorking Group (NNWG) would like tocongratulate Don Roth for wining the R&D100Award. This award is for the development of asingle transducer imaging method for thickness-independent velocity measurements. Congratulations Don!!!.
Yoseph Bar-Cohen elected ASNT Fellow - InApril 96, the ASNT Awards Committee selectedand the Board of Directors approved Bar-Cohen asthe recipient of the ASNT Fellow Award. TheAward will be given officially at the ASNT FallConference that will be held in Oct. 96 in Seattle,Washington.
NASA CENTERS NEWS
JPLYoseph Bar-Cohen, 818-354-2610, [email protected]://nasa-nde.jpl.nasa.gov/jpl-nde/nde-aa-l/nde-aa-l.htm
VISIT TO McCLELLAN AIR-FORCE BASE -In June, Soheil Nazarian, University of Texas at ElPaso (UTEP), and Yoseph Bar-Cohen visitedMcClellan Air Force Base for facts findingregarding Air Force NDE needs and their mostrecent testing technology. This effort is part of anongoing contract with AFOSR. Al Rogel hosted
this visit and gave the visitors a tour of the aircraftmaintenance facility as well as the various NDElaboratories. The laser ultrasonic system, thatbecame operational in March 1996, received themost attention during this visit. This is a newsystem and McClellan AFB was the first toimplement it to a practical use. This new systemfollows a history of taking a lead in implementingnew technology at McClellan AFB. This AFB hasbeen the first to install an advanced robotic facilityfor large area inspection using X-ray and neutronradiography where a full aircraft is being testedwithout disassembly. Al Rogel is following closelythe recent development of the JPL’s MACStechnology.
Soheil Nazarian, UTEP (right) and Yoseph Bar-Cohen, JPL (Left) hosted by Al Rogel (middle) atMcClellan AFB.
Tom Kwan, McClellan AFB, is operating the newlaser ultrasonic scanner.
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Multifunction Automated Crawling System(MACS) on the C-5 airplane [Patent Pending].
MACS TO BE DEMONSTRATED TO A JPLHIGH LEVEL DoD VISITOR - On August 15,1996, the Honorable R. Noel Longuemare, thePrincipal Deputy UnderSecretary for Acquisition &Technology, Department of Defense will visit JPLfor a day to see demonstrations of selectedtechnologies. Out of the wide variety ofimpressive technologies that JPL has developed inrecent years, the Honorable visitor chose severalitems for his agenda including the MultifunctionAutomated Crawling System (MACS). MACS[Patent Pending], which was reported in priorissues of this Newsletter, is a miniature crawlerthat was designed for inspection of aircraftstructures using telerobotic technology that isdeveloped for Mars exploration. It uses ultrasonicmotors for its mobility and vacuum suction cupsfor controlled adherence. In parallel to the ongoingefforts to enhance the capability of MACS, aninitiative is underway to adapt this technology tospace applications. Jointly with Bill Prosser,LaRC, a wireless acoustic emission sensortechnology is being explored. Whereas, jointlywith Min Namkung, an initiative is beingconsidered for the development of an AutonomousMiniature TeleRobotic Inspector (AMTRI).
NDE OF COMPOSITES COLLABORATIONWITH LeRC AND KSC - Under a Code QRTOP, JPL is developing jointly with EricMadaras, LaRC, a system for Ultrasonic NDE ofthe Integrity and Performance of Composites
(UNIPC). A user-friendly software for materialanalysis and C-scan mapping is being developed. The end goal of this program is to demonstratethe performance, simplicity of operation andpracticality of UNIPC by testing NASA criticalcomposite structures. In order to nondestructivelyexamine the material density and porosity content,the use of CT analysis to supplement ultrasonicmeasurements has been explored in collaborationwith George Baaklini, LeRC and, John Larson,KSC. Graphite/epoxy defect-free controlledsamples (provided by John Taylor, Rohr) as wellas samples with extensive porosity that were madefor Mars Pathfinder are being studied. Series oftests were made and the density distribution wasmapped in various cross sections of the samples.
CT image of the density distribution in a referencegraphite/epoxy sample.
COMPOSITE MATERIALS ARE NOW A$47M PROGRAM AT JPL - Recent review ofthe JPL level of programs that employ compositematerials showed a sharp rise to a level of morethan $47M. This is a significant milestone sincespace exploration is very sensitive to the reliabilityof the construction materials and there is nosecond chance to a failure. The significantimprovement in the material quality, durability andinspection led this recent increase. To assurecontinuous improvement of the inspectioncapability and reliability while reducing inspectioncost, JPL is involved in a joint RTOP with LaRCto develop a system of an Ultrasonic NDE of theIntegrity & Performance of Composites (UNIPC).
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INTEGRATED HEALTH MONITORINGSYSTEM FOR S/C APPLICATIONS - In June,Innovative Dynamics, Inc. (IDI) completed thePhase II SBIR contract with JPL. The contract isentitled “Development of Integrated HealthMonitoring System for Spacecraft Applications,”and the JPL Technical Monitor is Yoseph Bar-Cohen. A system was developed to monitorinception of damage in composite structures,where an imbedded set of transmitters andreceivers are used to excite vibrations, as well asdetect and analyze them.
Tianji Xue joined theJPL’s NDE&AATeam as a Postdoc.
TIANJI XUE, A NEW MEMBER OF THEJPL’s NDE&AA TEAM - In June, 1996, TianjiXue joined the JPL’s NDE&AA Team after hecompleted the requirements of his Ph. D. degree. Xue received his BS degree in Optical Engineeringfrom the Beijing Institute of Technology, and hisMS and Ph.D. degrees in Electrical Engineeringfrom Iowa State University. Xue has experience inultrasonic wave propagation with application tonondestructive evaluation semiconductor and thinfilm devices design and characterization; opticalsystem design, image formation and processing;and numerical modeling of electromagnetic. AtJPL, Xue is working on NDE of Composites aswell as the development of electroactive polymersfor muscle actuators
THE NDE & ADVANCED ACTUATORS(AA) TEAM RECORDED 4 PATENTSPENDING SINCE FEB. 1996 - Four NewTechnology Reports of the NDE&AA team wereofficially submitted to the Patent Office inWashington and are now Patent Pending. Theseinventions involve the use of piezoelectric elementsas actuators and they include:
Y. Bar-Cohen, "Pump Using Pistons and ValveMade Of Electroactive Actuators", Patent Pending,CIT 2427, Feb. 9, 1996.
Y. Bar-Cohen, S.-S. Lih and W. Grandia, "HighTorque Ultrasonic Motor System Using a Series ofConnected Individual Motors and a Stack ofPiezoelectric Drivers," Patent Pending, CIT 2428,Submitted on April 17, 1996.
Y. Bar-Cohen, B. Joffe and S.-S. Lih "FlexuralTraveling Wave Pump Using No PhysicallyMoving Parts", Patent pending, CIT 2456,Submitted on June 25, 1996.
Y. Bar-Cohen, B. Joffe and P. Backes"Multifunction Automated Crawling System(MACS)", Patent Pending, CIT 2432, Submittedon August 1, 1996.
NDE OF COMPOSITE STANDARDS - JPLjust completed issuing a series of NDE ofcomposite standards. These standards include ageneral document and two specific ones that coverultrasonics and radiography. These documentsissued by Bar-Cohen were reviewed NASA-wideand by selected individuals from the industry andDoD. This recent effort was taken as the first stepbefore transition of these standards to non-government standard (NGS) organizations. Thegeneral trend in government forming standards isto issue a document only when no other exists andto transfer the existing to NGS organizations. Thistrend was also one of the decisions that were madeby the NASA M&P Standards Working Group inits last meeting that was held in July 1996 at KSC.
NAMKUNG, LaRC, VISITED THE JPL’sNDE&AA LAB TO DISCUSSCOOPERATION IN MINIATURE ROBOTICNDE - In July, Min Namkung visited the JPL’sNDE & AA Lab to discuss a cooperation in thearea of miniature robotic NDE. The extensive JPLinvolvement in TeleRobotics and its successfuldevelopment of MACS produced enablingtechnology for an Autonomous MiniatureTeleRobotic Inspector (AMTRI). AMTRI iscurrently being designed for space applications and
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whenever possible it will use commerciallyavailable components. The CrackFinder andcontrolled adherence are some of the technologiesthat LaRC is offering to this potential cooperation.
GEORGE MATZKANIN VISIT THENDE&AA LAB - In July, George Matzkanin,Director, NTIAC, Austin, TX, visited theNDE&AA Lab. The purpose of the visit was todiscuss potential collaboration in a spectrum ofareas of NDE including aging aircraft, informationnetworking, etc.
ROBERTO OSEGUEDA VISIT THENDE&AA LAB - In July, Roberto Osegueda, thedirector of FAST Center at the University of Texasat El Paso, visited JPL in July. JPL and UTEPcurrently have a joint contract from AFOSR. During his visit Osegueda was given ademonstration of the recent progress that theNDE&AA Lab made in the areas of NDE ofcomposites, NDE of aging aircraft technology,MACS, as well as in the use of piezoelectric andelectrostrictive materials for actuation applications.
NDE OF MICROELECTONICS FOR THENEW MILENNIUM PROGRAM (Barela,D’Agostino and Bar-Cohen) - The JPL’s MarsMicroprobe is entirely an application of micro-electronics. The probe is an assembly of varioushigh-density packaging integrated with a unifiedhigh-density interconnect scheme. NDE is criticalto the success of this application. JPL took aninitiative to develop effective NDE techniques andqualified procedures of assuring the quality of theelements of its electronic assemblies. This effort isgoing to be funded partially by the NDE Programof Code Q in FY’97. In addition to benefiting theMars Microprobe, advancement of the NDEtechnology into the field of high-density electronicpackaging and interconnection will serve all ofNASA's future missions including Micro-electronicMechanical Systems (MEMS) that is currentlyconsidered for implementation in a wide range ofapplications.The Microprobe will experience very highaccelerations as it enters the Martian atmosphere
and as it impacts the surface of Mars. It isestimated that this acceleration will be on theorder of 10,000 G's at the forward body andpossibly up to 80,000 G's for the aft body. Tosuccessfully design electronic packages for "highG" applications, it is of the utmost importancethat all the details of assembly be verified.
JSCMarie Havican, [email protected] TECHNOLOGY OUTREACH EFFORT - JSC is planning a major event, scheduled for threedays in November 1996, to reach out to industryand businesses that are not normally part of thespace-oriented community. It is called JSCINSPECTION, and will consist of up to 3000invited people, with 500 guests for each half-dayvisit. The objectives of the JSC Inspection aredecidedly different from those of an open house;we will showcase technology that may havecommercial applications. Some of the majorobjectives are:1. Communicate the results of our work to give
businesses ideas about how they can use ourtechnology to do what they do better or moreprofitably.
2. Exhibit work that could interest a firm inpartnering with us in dual-use technologydevelopment.
3. Showcase JSC-developed technologies that areavailable for licensing.
4. Display unique facilities that could be used on areimbursable basis.
KSC
John Larson, [email protected] NDE LAB COLLABORATION WITHJPL, LaRC, LeRC and MSFC - Recent activitiesat KSC include cooperative support efforts withJPL, LeRC, LaRC and MSFC. All efforts involveutilization of the KSC’s Computed Tomographysystem providing additional data to ongoingstudies. Support to a JPL - LeRC effort involvedCT scans of a composite being utilized indevelopment of ultrasonic techniques. Support toLaRC involved CT analyses of crystal growth
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experiments flown on STS-78. Data producedincluded digital radiographs, CT slices and 3Dimages. Information gained from the dataprovided to LaRC has resulted in MSFCrequesting similar analyses on six samples. Thesupport to MSFC is in process. If the data provesas significant, ESA has expressed an interest inobtaining similar analyses.
LaRCEric Madaras, [email protected] TECHNIQUE DEVELOPED TOMEASURE RELAXATION PROCESSES INPOLYMERS (Yost) - A new more accuratetechnique to measure relaxation processes inpolymers has been developed. This techniquepermits contactless measurement of ultrasonicattenuation whose temperature dependence isuseful in the study of internal friction in polymersand metals. It is also expected to give additionalinsights into aging and service life effects in metalsand polymers.
DEMONSTRATION OF LOW COST NDE ATSTODDARD HAMILTON AIRCRAFT, Inc.(Cramer) - A low cost thermal NDE techniquedeveloped by the Nondestructive EvaluationSciences Branch was successfully demonstrated atStoddard Hamilton Aircraft, Inc. in Arlington,Washington, on June 12 and 13, 1996. Thetechnique uses a commercially available device,designed for medical imaging, that usestemperature sensitive liquid crystal sheets to sensethe temperature changes that occur in fiberglasswing and fuselage components as they are activelyheated by quartz lamps. The resulting images canbe recorded either digitally or photographically forarchival purposes. Inspections were made on threedifferent aircraft at several fuselage and winglocations of concern for the manufacturer.
MEASUREMENT SYSTEM DELIVERED TOCLINICAL PARTNER (Yost and Cantrell) - Ameasurement system which uses ultrasonics toidentify key tissue types in patients with bedsoreswas delivered to George Taler at Deaton Hospitalin Baltimore, Maryland. The researchers also have
identified the bedsore-related tissue types and theirtransition zones from unique ultrasonic signaturesobtained with this system. The instrument is basedon LaRC-developed instrumentation designed fornondestructive analysis of polymeric matrixcomposite materials.
INTRACRANIAL PRESSURE (ICP)STUDIES FUNDED BY ARMY (Cantrell andYost) - The joint Langley-Ames effort to developin ultrasonic technique for the noninvasivemeasurement of intracranial pressure an humanshas received a boost from the Army, with theannouncement of award of the proposal,"Noninvasive Intracranial Volume and PressureMeasurements Using Ultrasound" . The proposalwill fund Alan Hargens' group to test theinstrumentation at Ames Research Center. Theeffort will result in a design for a field readynoninvasive ICP monitoring system for the Army.
MEETING OF ASTM COMMITTEE E-7 ONNONDESTRUCTIVE TESTING (Hinton) -Yolanda Hinton attended a meeting of ASTMCommittee E-7 on Nondestructive Testing, whereshe chairs Subcommittee E07.04 AcousticEmission. The committee is responsible for morethan 130 standards on different methods ofnondestructive testing and their applications. Thecommittee maintains liaison with DoD for theconversion of Defense standards to commercialones. In light of the new law that requiresgovernment agencies to use commercial standardswhere available, the committee will seek formalliaison with NASA as well. The Acoustic Emissionsubcommittee is planning the Fifth InternationalSymposium on Acoustic Emission: AcousticEmission Standards and Technology Update, forJanuary 1998.
VISIT BY PERSONNEL OF McDONNELLDOUGLAS AND KRAUTKRAMERBRANSON (Namkung) - Bruce Bates ofMcDonnell Douglas visited NESB on May 20,1996, to learn the technical details of the variousversions of the self-nulling eddy current sensorprototype instruments. He was particularlyinterested in the simplicity in the operation of the
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rotating self-nulling probe and is looking forwardto receiving a prototype unit from NESB for anextensive evaluation. He was met by Mr. ArtLeach of Krautkramer Branson, commercializationpartner of the self-nulling probe, who brought arecently modified CrackFinder with the adjustablegain control feature. Mr. Bates was pleased to seethe progress in the CrackFinder and providedcomments for further improvement. He alsoinvited the key individuals in the E&M group tovisit the MD facility to try the rotating probe suchthat its applicability can be clearly defined for thereal world test environment.
ACOUSTIC EMISSION MONITORING OFSIMULATED MICROMETEOROIDIMPACTS ON X-33 COMPOSITEMATERIALS (Prosser and Humes) - AcousticEmission (AE) was used to monitor high velocityimpact tests of composite plates for Lockheed-Martin as part of the X-33 program. Compositesof the minimum and maximum thickness currentlydesigned for cryogenic fuel tanks were tested. Atwo stage, light gas gun was used to create impactsat velocities ranging from 2 to 6 km/sec. with 1.5mm diameter nylon projectiles. Preliminaryanalysis indicates that penetrating impacts can beclearly differentiated from nonpenetrating impactsbased on AE signal characteristics. These testsalso provide a basis for calculating desired sensorspacing for an on-orbit micrometeoroid and spacedebris impact monitoring system.
ACOUSTIC EMISSION MONITORING OFNORTHROP/ROCKWELL RLV WINGBOXTEST (Prosser) - Acoustic Emission (AE) wasused to monitor damage progression during thestatic load testing of the Northrop/ Rockwell RLVcomposite wingbox test article. Fourteen sensorswere monitored, eight using a NASA LaRC AEsystem and six with a similar Northrop system. The regions monitored by these sensors were theupper wingskin and a portion of the middle sparflange. The cantilevered wingbox was pushed upto limit and ultimate loads, pulled down to limitand ultimate loads, and then at a later date, thewingbox was pushed up to failure. When thespecimen was pulled down, the area monitored by
AE was in tension and AE activity was muchhigher. These AE signals were characteristic ofmatrix cracking, but the actual damage mechanismwas not confirmed. When the wingbox waspushed up and the region monitored was undercompression, the level of AE was very low, evenup to failure. Although the actual signal fromultimate failure was easily detected and localized,AE signals were not detected from this locationbefore failure to provide prior warning. There areseveral reasons for this including the sudden,catastrophic failure behavior of composites undercompression, the relatively large distance of thefailure site from the nearest sensor position, andthe low signal gain settings. Northrop determinedsensor positions and signal gain based on previoustests of smaller compression test panels.
PATENT AWARDED (Zalameda) - Patent No.5,508,546, "Active Pyroelectric Infrared Detector"by Joseph N. Zalameda, Allan Zuckerwar, andJoseph Mina was awarded April 16, 1996.
SAM RUSSELL VISITS NESB (Heath 44964) -Sam Russell of MSFC (Marshall Space FlightCenter) visited NESB (Nondestructive EvaluationSciences Branch) on May 6, 1996. The day wasspent discussing current cooperative efforts andplanning future directions in thermographic NDEfor the Code Q program. Elements of the NESBdeveloped thermography system were identified asimportant for MSFC applications, and plans fortransferal of the LaRC technology to Marshall'snewly started thermography program werediscussed. Russell also met with Ed Generazio,Code Q NDE Program Manager, to discuss thesuccesses of MSFC's Thermographic andShearographic NDE RTOPS.
NEW VERSION OF CRACKFINDERBECOMES AVAILABLE (Namkung) - Thehand-held CrackFinder, which has beencommercially available to date, had an excessivedetection sensitivity since the manufacturer,Krautkramer Branson, wanted to emphasize itsdetectability of extremely shallow surface cracks. It turned out that such a high sensitivity, however,creates more difficulties related to probe wobble
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and liftoff, significantly reducing its practicalapplicability. Upon the suggestions made by theindividuals of the NESB Electromagnetics Group,the firm finally produced a prototype with avariable gain. This prototype can be configured asa sliding probe rapidly detecting almost invisiblefatigue cracks in the lap joints without beingaffected by probe wobbles and a sensitive probethat can detect shallow surface cracks. The newprobe has been presented to General Dailey duringhis visit to LaRC, and was shown to Bruce Bates,McDonnell Douglas during his visit to NESB onMay 20, 1996.
ENGINE TITANIUM CONSORTIUM OPENFORUM (Johnston) - Patrick Johnston of theNondestructive Evaluation Science Branchparticipated in an Open Forum of the EngineTitanium Consortium, sponsored by the FAATechnical Center and FAA New England Engineand Propeller Directorate, in San Francisco,California, on May 8-10, 1996. The Forumpresentations focused on recent developments andplanned activities toward improvement ofinspection of titanium billets and forging for hardalpha inclusions, which can lead to catastrophicfailure of jet engine components if not detected. The primary methodology for inspecting the bulkmaterial is ultrasonics, with eddy current testingemployed for detecting surface cracks. Areas wereidentified where NASA developments in ultrasonicarray technology, eddy current technology, andradiography might play constructive roles. Contacts were made for follow-up.
U. S. ARMY LOGISTICS SCHOOLNONDESTRUCTIVE INSPECTIONPROGRAM VISITS NESB (Anastasi, Cmar,Hinton, Roberts, and Zalameda) - On April 22,1996, the Nondestructive Inspection program ofthe U. S. Army Logistics School, Fort Eustis,Virginia, visited the Nondestructive EvaluationSciences Branch's Bob Anastasi, Noreen Cmar,Yolanda Hinton, Mark Roberts, and Joe Zalameda.The purpose of their visit was to tour our facilitiesand to discuss inspection concerns. An overviewtalk was given by branch head Ed Generazio andlaboratory demonstrations were given by Bob
Anastasi, Noreen Cmar, Pat Johnston, MinNamkung, and Joe Zalameda.
NESB MEMBERS VISIT U. S. ARMYCOMBINED ARMS SUPPORT COMMAND (Zalameda, Hinton and Farley) - Joe Zalameda,Yolanda Hinton, and Gary Farley visited the U. S.Army Combined Arms Support Command(CASCOM) at Fort Lee, Virginia, on May 2, 1996. They discussed a proposed joint program todevelop, evaluate, and demonstrate anondestructive diagnostic tool for the detection ofpotential failures in powertrain components ofArmy vehicles. The system would use chosenNDE methods to characterize signatures from thecomponents, and monitor changes in thesesignatures as indication of impending failure.
VISITORS FROM ARINC ARE BRIEFED ONASIP CORROSION PROGRAM. (Cramer)-John Alcott and Christian O'Keefe visited NESBon May 1-2, 1996, to discuss progress that hasbeen made on quantification of corrosion in thinaluminum skins. ARINC is currently investigatingresearch into corrosion detection andquantification for Tinker Air Force Base. Discussions and demonstrations were made byresearchers in the areas of Thermal, Ultrasonic,and Eddy Current NDE.
DELTATHERM TECHNOLOGYDEMONSTRATED ON GENERALAVIATION COMPONENTS FORRAYTHEON AIRCRAFT (Cramer) - SteveHagerott and Bryce Boe from Raytheon Aircraftvisited NESB on May 2-3, 1996, to view testsbeing conducted on Raytheon general aviationaircraft parts as a demonstration of the capabilitiesof the DeltaTherm 1000. The DeltaTherm 1000was developed under an SBIR by Stress Photonics,Inc. and is currently being used by NESBresearchers for thermoelastic stress imaging. Theresults obtained during the current testing will becompared with finite element models generated byRaytheon to determine the feasibility of using theDeltaTherm 1000 as a design verification tool forgeneral aviation aircraft. This interactiondemonstrates the transfer of ASIP developed
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technology for use in other NASA and commercialprograms such as the AGATE Program.
VISITING NDE SCIENTIST FROMGENERAL ELECTRIC (Namkung) - James P.Fulton of General Electric Corporate Research andDevelopment Center visited NESB(Nondestructive Evaluation Sciences Branch)Electromagnetic Group during the period April 25-May 1, 1996, to perform joint laboratoryexperiments necessary to gain a deeper insight intovarious phenomena involved in eddy current NDE. The current mutual interest is to define andenhance the fatigue crack detectability of self-nulling eddy current probes for objects havingdifferent electric conductivity and magneticpermeability without being affected by probewobble. A series of experiments were performedand the results were reported at the QNDEConference held in July 1996. Another subject ofmutual investigation is to clarify the issues relatedto the dynamics of electromagnetic field inside aconducting medium. A new approach to thisproblem has been discussed and the steps ofsystematic investigation have been established.
LeRCGeorge Baaklini, [email protected] D. J. Roth, 216-433-6017SINGLE TRANSDUCER ULTRASONICIMAGING METHOD FOR THICKNESS-INDEPENDENT VELOCITYMEASUREMENTS WINS 1996 R&D100AWARD - Don Roth has commercialized thismethod under a cooperative agreement betweenNASA Lewis Research Center and Sonix, Inc.The use of this method can result in significantcost savings during material development. Addedprecision thickness machining are no longerneeded to satisfy nondestructive ultrasoniccharacterization. Images obtained using thethickness-independent methodology werecompared with apparent velocity maps andc-scan echo peak amplitude images formonolithic ceramic , metal matrix composite andpolymer matrix composite materials having thickness and global microstructural variations.
Results showed that the thickness-independentultrasonic images reveal and quantify true areasof global microstructural variations like pore andfiber volume fraction due to the elimination ofthickness effects.
MSFCSam Russell 205-544-4411, [email protected] INSPECTION SPECIFICATIONS (SamRussell) - At the request of Mr. Chris Davis ofKSC, the first and second drafts of the “ShuttleOrbiter Thermography Inspection Specification”were reviewed and edited. Changes weretransmitted to A. M. Koshi of RockwellInternational, the document’s author. Also, a firstdraft of a “Shuttle Orbiter ShearographyInspection Specification” has been sent to us forediting .
NDE OF XCRV COMPOSITE PANELS (SamRussell) - This effort is to help JSC decide themethod and detectability limits to use to inspect theAssured Crew Return Vehicle (XCRV) aeroskinand other composite components. At the requestof Mr. David Stanley of JSC, 12 graphite-epoxypanels which contained programmed defects wereinspected with flash and through heatedthermography. The face sheet panel containeddefects at Teflon inclusions of 2, 1, 0.5, or 0.25inches in diameter, one of each size placed at depthof 10, 30, or 50 % of the thickness (0.075 in.) ofthe panel. This panel was inspected from each sideand hence detectability of defects usingthermography from diameters 2 inches to 0.25inches and located from 10% to 90% of thethickness was successfully determined. The other11 panels were graphite skin with Nomex coresimilar to the Shuttle Payload Door material whichcontained programmed defects at the honeycombto skin interface. One of these was a calibrationpanel which came with a defect map. All panelswere inspected and all programmed defects in thecalibration panel were detected. Thermographyimages and defect maps were provided to Mr.Stanley. Shearography and ultrasonic inspectionare also being performed on these panels.ATD INSULATION INSPECTION (SamRussell) - The advanced turbopump insulation is to
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be formed by DuPont on the metal housings attheir facility in Newark, Del. The housing’sinsulation is composed of a layer of choppedKevlar fiber urethane insulation (KFUI) betweentwo layers of Kevlar cloth and urethane. Eachbondline must be inspected and hence inspection isbest performed after application of each layer. Inspection of a test bottle covered with KFUIcontaining programmed defects with shearographyand vacuum stressing several years ago wassuccessful. Hence shearography is the leadingcandidate for inspection. DuPont does not have ashearography system and plans to ship the first fewhousings to Laser Technology Inc. (LTI) forinspection at intermediate steps. MSFC has twoshearography systems and plans to loan a system toDuPont for the two year program. This wouldenable inspection to be performed more frequentlyin the process and would eliminate potentialshipping induced damage. Pratt and Whitney(P&W), the prime contractor has committed towork an equitable adjustment to the ATD contractfor the loan of the MSFC shearography system toDuPont. DuPont has a FLIR Thermographiccamera and X-radiographic capability that mightbe used for inspection of some of the otherinsulation pieces not bonded to the housings. DuPont is to make test panels containing defectsand ship them to MSFC. MSFC NDE willevaluate the panels with shearography,thermography, and radiography and makerecommendations to DuPont regarding the bestinspection methods for each insulation type.
DEVELOPMENT OF NDE FOR FRICTIONSTIR WELDING (FSW) RTOP STATUS(Linda Clark and Mike Suits) - Inputs from NDE,Quality and Welding personnel at MSFC have beencompiled to generate a schedule detailing the tasksto be completed under the RTOP. LockheedMartin (LM) at Michoud Assembly Facility (MAF)is currently working a Special Development Study(SDS) which involves the development of the FSWplug repair process. The RTOP at MSFC willinclude support for the FSW plug repair process,development of linear FSW repair welds, and thefabrication of NDE standards for both processes. MSFC and LM personnel have compared
schedules and tasks in an effort to integrate theNDE work proposed in both the RTOP and SDS. An assessment of the NDE capabilities andequipment of MSFC and LM was used to assignthe NDE tasks to be completed for both the RTOPand SDS. MSFC and LM personnel are workingtogether to decide what work will besubcontracted. MSFC and LM personnel are inthe process of assessing the amount of 2195aluminum-lithium material (along with variousthickness) available in an effort to determine howmuch additional material needs to be procured. Assoon as this assessment is complete, work willbegin to support both the RTOP and SDS. Ameeting was held on July 31, 1996 at MSFC tofinalize the integration of both the RTOP and SDSschedules. MSFC’s Welding Group is in theprocess of becoming a member of the GroupSponsored Project (GSP) in an effort to obtainresults from the Phase III work completed at TheWeld Institute (TWI). Phase III work involvesNDE of the FSW process on 2219 aluminum.
COMING EVENTS• Structures, Atlanta, GA., Director S.N. Atluri.• Oct. 14-18, 1996 - ASNT Fall Conference -
Seattle, Washington, ASNT Headquarters,614-274-6004.
• Dec. 3-5, 1996 - NDE Techniques for AgingInfrastructure & Manufacturing, Scottsdale,AZ. [email protected], http://www.spie.org/
• Dec. 8-13, 1996 - 14th World Conference onNDT - New Delhi, India, Baldev Raj, 04117-40301.
• Feb., 1997 - 4th NNWG Workshop - JPL,California, George Baaklini, 216-433-6016.
• Feb. 26-28, 1997 - Golden Gate MaterialsTechnology Conference, San Francisco, CA,Jerry Wittneauer 415-424-2243.
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JPL’s MarsPathfinder missionis scheduled forlaunch on Dec. 2,1996 and to landon Mars on July 4,1997. Compositecomponents of thislander were testedat the JPL’s NDE& AA Lab.
NASA NDE Working Group (NNWG) Newsletter Editor: Yoseph Bar-Cohen, JPL Assistant Editor: Marie Havican, JSC This NNWG Newsletter is published quarterly by the NNWG and NASA HQ, Code Q. NASA HQ, Code Q NDE Program Manager: Edward Generazio, LaRC. All communications should be addressed to: NNWG Newsletter, JPL, M.S. 82-105, 4800 Oak Grove Dr., Pasadena, CA 91109-8099 Phone: (818)-354-2610, FAX (818)-393-4057 or E-mail: [email protected]
