The Effect of Experimental Variables on Industrial X-Ray Micro-Computed Sensitivity

A study was performed on the effect of experimental variables on radiographic sensitivity (image quality) in x-ray micro-computed tomography images for a high density thin wall metallic cylinder containing micro-EDM holes. Image quality was evaluated in terms of signal-to-noise ratio, flaw detectability, and feature sharpness. The variables included: day-to-day reproducibility, current, integration time, voltage, filtering, number of frame averages, number of projection views, beam width, effective object radius, binning, orientation of sample, acquisition angle range (180deg to 360deg), and directional versus transmission tube

Ultrasonic Phased Array Simulations of Welded Components at NASA

Comprehensive and accurate inspections of welded components have become of increasing importance as NASA develops new hardware such as Ares rocket segments for future exploration missions. Simulation and modeling will play an increasing role in the future for nondestructive evaluation in order to better understand the physics of the inspection process, to prove or disprove the feasibility for an inspection method or inspection scenario, for inspection optimization, for better understanding of experimental results, and for assessment of probability of detection. This study presents simulation and experimental results for an ultrasonic phased array inspection of a critical welded structure important for NASA future exploration vehicles. Keywords: nondestructive evaluation, computational simulation, ultrasonics, weld, modeling, phased arra

Oxidation Through Coating Cracks of SiC-Protected Carbon/Carbon

The oxidation of SiC-protected carbon/carbon through machined slots and naturally occurring craze cracks in the SiC was studied. The slot and crack geometries were characterized, and the subsurface oxidation of the carbon/carbon substrate at temperatures of 1000 to 1300 C in air was assessed using weight change, x-ray computed tomography, and optical microscopy of sections. Rate constants were derived from these measurements and compared with a two-step diffusion control model of carbon oxidation. Oxidation kinetic measurements on both the specimens with machined slots and with naturally occurring craze cracks showed good agreement with the model

Terahertz Computed Tomography of NASA Thermal Protection System Materials

A terahertz axial computed tomography system has been developed that uses time domain measurements in order to form cross-sectional image slices and three-dimensional volume renderings of terahertz-transparent materials. The system can inspect samples as large as 0.0283 cubic meters (1 cubic foot) with no safety concerns as for x-ray computed tomography. In this study, the system is evaluated for its ability to detect and characterize flat bottom holes, drilled holes, and embedded voids in foam materials utilized as thermal protection on the external fuel tanks for the Space Shuttle. X-ray micro-computed tomography was also performed on the samples to compare against the terahertz computed tomography results and better define embedded voids. Limits of detectability based on depth and size for the samples used in this study are loosely defined. Image sharpness and morphology characterization ability for terahertz computed tomography are qualitatively described

Ultrasonic Phased Array Inspection Simulations of Welded Components at NASA

Comprehensive and accurate inspections of welded components have become of increasing importance as NASA develops new hardware such as Ares rocket segments for future exploration missions. Simulation and modeling will play an increased role in the future for nondestructive evaluation in order to better understand the physics of the inspection process and help explain the experimental results. It will also help to prove or disprove the feasibility for an inspection method or inspection scenario, help optimize inspections, and allow to a first approximation limits of detectability. This study presents simulation and experimental results for an ultrasonic phased array inspection of a critical welded structure important for NASA future exploration vehicles

Oxidation Through Coating Cracks of SiC-Protected Carbon/Carbon

The oxidation of SiC-protected carbon/carbon through machined slots and naturally occurring craze cracks in the SiC was studied. The slot and crack geometries were characterized, and the subsurface oxidation of the carbon/carbon substrate at temperatures of 1000 to 1300 C in air was assessed using weight change, x-ray computed tomography, and optical microscopy of sections. Rate constants were derived from these measurements and compared with a two-step diffusion control model of carbon oxidation. Oxidation kinetic measurements on both the specimens with machined slots and with naturally occurring craze cracks showed good agreement with the model

Novel Method Used to Inspect Curved and Tubular Structural Materials

At the NASA Lewis Research Center, a technique for the ultrasonic characterization of plates has been extended to tubes and to curved structures in general. In this technique, one performs measurements that yield a thickness-independent value of the local through-the-thickness speed of sound in a specimen. From such measurements at numerous locations across the specimen, one can construct a map of velocity as a function of location. The gradients of velocity indicated by such a map indicate local through-the-thickness-averaged microstructural parameters that affect the speed of sound. Such parameters include the pore volume fraction, mass density, fiber volume fraction (in the case of a composite material), and chemical composition. Apparatus was designed to apply the technique to tubular and other curved specimens

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 Inspectio

Oxidation of Carbon/Carbon through Coating Cracks

Reinforced carbon/carbon (RCC) is used to protect the wing leading edge and nose cap of the Space Shuttle Orbiter on re-entry. It is composed of a lay-up of carbon/carbon fabric protected by a SiC conversion coating. Due to the thermal expansion mismatch of the carbon/carbon and the SiC, the SiC cracks on cool-down from the processing temperature. The cracks act as pathways for oxidation of the carbon/carbon. A model for the diffusion controlled oxidation of carbon/carbon through machined slots and cracks is developed and compared to laboratory experiments. A symmetric cylindrical oxidation cavity develops under the slots, confirming diffusion control. Comparison of cross sectional dimensions as a function of oxidation time shows good agreement with the model. A second set of oxidation experiments was done with samples with only the natural craze cracks, using weight loss as an index of oxidation. The agreement of these rates with the model is quite reasona

NDE Software Developed at NASA Glenn Research Center

NASA Glenn Research Center has developed several important Nondestructive Evaluation (NDE) related software packages for different projects in the last 10 years. Three of the software packages have been created with commercial-grade user interfaces and are available to United States entities for download on the NASA Technology Transfer and Partnership Office server (https://sr.grc.nasa.gov/). This article provides brief overviews of the software packages