Microwave and Millimeter Wave Testing for the Inspection of the Space Shuttle Spray on Foam Insulations (SOFI) and the Acreage Heat Tiles

The utility of microwave and millimeter wave nondestructive testing and evaluation (NDT&E) methods, for testing the Space Shuttle's external he1 tank spray on foam insulation (SOFI) and the acreage heat tiles has been investigated during the past two years. Millimeter wave NDE techniques are capable of producing internal images of SOFI. This paper presents the results of testing several diverse panels with embedded voids and debonds at millimeter wave frequencies. Additionally, the results of testing a set of heat tiles are also presented. Finally, the attributes of these methods as well as the advantageous features associated with these systems are also provided

Microwave and Millimeter Wave Nondestructive Evaluation of the Space Shuttle External Tank Insulating Foam

The Space Shuttle Columbia s catastrophic failure has been attributed to a piece of external fuel tank insulating SOFI (Spray On Foam Insulation) foam striking the leading edge of the left wing of the orbiter causing significant damage to some of the protecting heat tiles. The accident emphasizes the growing need to develop effective, robust and life-cycle oriented methods of nondestructive testing and evaluation (NDT&E) of complex conductor-backed insulating foam and protective acreage heat tiles used in the space shuttle fleet and in future multi-launch space vehicles. The insulating SOFI foam is constructed from closed-cell foam. In the microwave regime this foam is in the family of low permittivity and low loss dielectric materials. Near-field microwave and millimeter wave NDT methods were one of the techniques chosen for this purpose. To this end several flat and thick SOFI foam panels, two structurally complex panels similar to the external fuel tank and a "blind" panel were used in this investigation. Several anomalies such as voids and disbonds were embedded in these panels at various locations. The location and properties of the embedded anomalies in the "blind" panel were not disclosed to the investigating team prior to the investigation. Three frequency bands were used in this investigation covering a frequency range of 8-75 GHz. Moreover, the influence of signal polarization was also investigated. Overall the results of this investigation were very promising for detecting the presence of anomalies in different panels covered with relatively thick insulating SOFI foam. Different types of anomalies were detected in foam up to 9 in thick. Many of the anomalies in the more complex panels were also detected. When investigating the blind panel no false positives were detected. Anomalies in between and underneath bolt heads were not easily detected. This paper presents the results of this investigation along with a discussion of the capabilities of the method used

On the Mutual Coupling Between Circular Resonant Slots

For near- and far-field microwave imaging purposes, array of circular resonant slots can be utilized to sample the electric field at a given reference plane. In general, the sensitivity of such array probes is impaired by the mutual coupling present between the radiating elements. The mutual coupling problem poses a design tradeoff between the resolution of the array and its sensitivity. In this paper, we investigate the mutual coupling between circular resonant slots in conducting ground plane both numerically and experimentally. Based on the analysis of the dominant coupling mechanism, i.e., the surface currents, various remedies to reduce the slots' mutual coupling are proposed and verified

Millimeter Wave Detection of Localized Anomalies in the Space Shuttle External Fuel Tank Insulating Foam and Acreage Heat Tiles

The Space Shuttle Columbia's catastrophic accident emphasizes the growing need for developing and applying effective, robust and life-cycle oriented nondestructive testing (NDT) methods for inspecting the shuttle external fuel tank spray on foam insulation (SOFI) and its protective acreage heat tiles. Millimeter wave NDT techniques were one of the methods chosen for evaluating their potential for inspecting these structures. Several panels with embedded anomalies (mainly voids) were produced and tested for this purpose. Near-field and far-field millimeter wave NDT methods were used for producing millimeter wave images of the anomalies in SOFI panel and heat tiles. This paper presents the results of an investigation for the purpose of detecting localized anomalies in two SOFI panels and a set of heat tiles. To this end, reflectometers at a relatively wide range of frequencies (Ka-band (26.5 - 40 GHz) to W-band (75 - 110 GHz)) and utilizing different types of radiators were employed. The results clearly illustrate the utility of these methods for this purpose

Sources of and Remedies for Removing Unwanted Reflections in Millimeter Wave Images of Complex SOFI-Covered Space Shuttle Structures

In the recent years, continuous-wave near-field and lens-focused millimeter wave imaging systems have been effectively used to demonstrate their utility for producing high-resolution images of metallic structures covered with spay on foam insulation (SOFI) such as the Space Shuttle external fuel tank. However, for some specific structures a certain interference -pattern may be superimposed on the produced images. There are methods by which the influence of this unwanted interference can be reduced, such as the incorporation of an incidence .angle and the proper use of signal polarization. This paper presents the basics of this problem and describes the use of the methods for reducing this unwanted influence through specific examples

Inspection of the Space Shuttle External Tank SOFI Using Near-Field and Focused Millimeter Wave Nondestructive Testing Techniques

The Space Shuttle Columbia's catastrophic failure has been attributed to a piece of external tank SOFI (Spray On Foam Insulation) striking the left wing of the orbiter causing significant damage to some of the reinforced carbon/carbon leading edge wing panels. Subsequently, several nondestructive testing (NDT) techniques have been considered for inspecting the external tank. One such method involves using millimeter waves which have been shown to easily penetrate through the foam and provide high resolution images of its interior structures. This paper presents the results of inspecting three different SOFI covered panels by reflectometers at millimeter wave frequencies, specifically at 100 GHz. Each panel was fitted with various embedded anomalies/inserts representing voids and unbonds of diferent shapes, sizes and locations within each panel. In conjunction with these reJqectome&rs, radiators including a focused lens antenna and a small horn antenna were used. The focused lens antenna provided for a footprint diameter of approximately 1.25 cm (0.5") at 25.4 cm (10") away from the lens surface. The horn antenna was primarily operated in its near-field for obtaining relatively high resolution images. These images were produced using 2 0 scanning mechanisms. Discussions of the difference between the capabilities of these two types of antennas (radiators) for the purpose of inspecting the SOFI as it relates to the produced images are also presented

Millimeter Wave Detection of Localized Anomalies in the Space Shuttle External Fuel Tank Insulating Foam

The Space Shuttle Columbia's catastrophic accident emphasizes the growing need for developing and applying effective, robust and life-cycle oriented nondestructive testing (NDT) methods for inspecting the shuttle external fuel tank spray on foam insulation (SOFI). Millimeter wave NDT techniques were one of the methods chosen for evaluating their potential for inspecting these structures. Several panels with embedded anomalies (mainly voids) were produced and tested for this purpose. Near-field and far-field millimeter wave NDT methods were used for producing images of the anomalies in these panels. This paper presents the results of an investigation for the purpose of detecting localized anomalies in several SOFI panels. To this end, reflectometers at a relatively wide range of frequencies (Ka-band (26.5 - 40 GHz) to W-band (75 - 110 GHz)) and utilizing different types of radiators were employed. The resulting raw images revealed a significant amount of information about the interior of these panels. However, using simple image processing techniques the results were improved in particular as it relate s to detecting the smaller anomalies. This paper presents the results of this investigation and a discussion of these results

A Novel 24 GHz One-Shot, Rapid and Portable Microwave Imaging System

Development of microwave and millimeter wave imaging systems has received significant attention in the past decade. Signals at these frequencies penetrate inside of dielectric materials and have relatively small wavelengths. Thus. imaging systems at these frequencies can produce images of the dielectric and geometrical distributions of objects. Although there are many different approaches for imaging at these frequencies. they each have their respective advantageous and limiting features (hardware. reconstruction algorithms). One method involves electronically scanning a given spatial domain while recording the coherent scattered field distribution from an object. Consequently. different reconstruction or imaging techniques may be used to produce an image (dielectric distribution and geometrical features) of the object. The ability to perform this accurate~v and fast can lead to the development of a rapid imaging system that can be used in the same manner as a video camera. This paper describes the design of such a system. operating at 2-1 GHz. using modulated scatterer technique applied to 30 resonant slots in a prescribed measurement domain

A Real-Time Microwave Camera at 24 GHz (K-Band}

The objective is to design and build a real-time microwave imaging system (i.e., camera) Microwave imaging offers tremendous potential in many applications: a) Inspection of low-loss composites, radomes, etc.; b) Detection and evaluation of corrosion under paint; c) Security, contraband detection. Raster scanning is slow and requires bulky mechanical systems. A real-time and portable imaging system can be extremely useful for rapid nondestructive testing of large structures

Millimeter Wave Holographical Inspection of Honeycomb Composites

Multi-layered composite structures manufactured with honeycomb, foam or balsa wood cores are finding increasing utility in a variety of aerospace, transportation, and infrastructure applications. Due to the low conductivity and inhomogeneity associated with these composites standard nondestructive testing (NDT) methods are not always capable of inspecting their interior for various defects caused during the manufacturing process or as a result of in-service loading. On the contrary, microwave and millimeter wave NDT methods are well-suited for inspecting these structures since signals at these frequencies readily penetrate through these structures and reflect from different interior boundaries revealing the presence of a wide range of defects such as disbond, delamination, moisture and oil intrusion, impact damage, etc. Millimeter wave frequency spectrum spans 30 GHz - 300 GHz with corresponding wavelengths of 10 - 1 mm. Due to the inherent short wavelengths at these frequencies, one can produce high spatial resolution images of these composites either using real-antenna focused or synthetic-aperture focused methods. In addition, incorporation of swept-frequency in the latter method (i.e., holography) results in high-resolution three-dimensional images. This paper presents the basic steps behind producing such images at millimeter wave frequencies and the results of two honeycomb composite panels are demonstrated at Q-band (33-50 GHz). In addition, these results are compared to previous results using X-ray computed tomography