Peter D. Juarez

Multi-frequency local wavenumber analysis and ply correlation of delamination damage.

Wavenumber domain analysis through use of scanning laser Doppler vibrometry has been shown to be effective for non-contact inspection of damage in composites. Qualitative and semi-quantitative local wavenumber analysis of realistic delamination damage and quantitative analysis of idealized damage scenarios (Teflon inserts) have been performed previously in the literature. This paper presents a new methodology based on multi-frequency local wavenumber analysis for quantitative assessment of multi-ply delamination damage in carbon fiber reinforced polymer (CFRP) composite specimens. The methodology is presented and applied to a real world damage scenario (impact damage in an aerospace CFRP composite). The methodology yields delamination size and also correlates local wavenumber results from multiple excitation frequencies to theoretical dispersion curves in order to robustly determine the delamination ply depth. Results from the wavenumber based technique are validated against a traditional nondestructive evaluation method.

Emerging Needs for Pervasive Passive Wireless Sensor Networks on Aerospace Vehicles

NASA is investigating passive wireless sensor technology to reduce instrumentation mass and volume in ground testing, air flight, and space exploration applications. Vehicle health monitoring systems (VHMS) are desired on all aerospace programs to ensure the safety of the crew and the vehicles. Pervasive passive wireless sensor networks facilitate VHMS on aerospace vehicles. Future wireless sensor networks on board aerospace vehicles will be heterogeneous and will require active and passive network systems. Since much has been published on active wireless sensor networks, this work will focus on the need for passive wireless sensor networks on aerospace vehicles. Several passive wireless technologies such as MEMS, SAW, backscatter, and chipless RFID techniques, have all shown potential to meet the pervasive sensing needs for aerospace VHMS applications. A SAW VHMS application will be presented. In addition, application areas including ground testing, hypersonic aircraft and spacecraft will be explored along with some of the harsh environments found in aerospace applications.

Carbon fiber TOW angle determination using microwave reflectometry

NASAs Advanced Composites Project is investigating technologies that increase automated remote inspection of aircraft composite structures. Therefore, microwave Frequency Domain Reflectometry (FDR) is being investigated as a method of enabling rapid remote inspection of angular orientation of the tow using microwave radiation. This work will present preliminary data demonstrating that frequency shifts in the reflection spectrum of a carbon fiber tow sample are indicative of the angle of the tow with respect to an interrogating antennas linear polarized output.

Far field measurements of small angle carbon fiber misalignments

Manufacturing of advanced composites for aircraft structures requires precise layups of carbon fiber tape. Currently visual inspection is the method used to determine if tape angle deviations are acceptable. Automated inspection during fabrication would decrease inspection times and therefore reduce costs. NASAs Advanced Composites Project is investigating technologies that increase automated remote inspection of aircraft composite structures. Therefore, microwave radiation is being investigated as a method of enabling rapid remote inspection of angular orientation of carbon fiber tow material. This work investigates the use of microwaves to measure the angle of carbon fiber tape misalignment using a far field technique.

Remote strain sensing of CFRP using microwave frequency domain reflectometry

NASAs Advanced Composites Project is investigating technologies that increase automated remote inspection of aircraft composite structures. Therefore, microwave Frequency Domain Reflectometry (FDR) is being investigated as a method of enabling rapid remote measurement of strain occurring at the first ply of a composite fiber reinforced polymer (CFRP) structure using Radio Frequency (RF) Electro-Magnetic (EM) radiation. While microwave reflectometry has been used to detect disbonds in CFRP structures, its use in detecting strain has been limited. This work will present data demonstrating the measurement of the reactance changes due to loading conditions that are indicative of strain in a CFRP structure. In addition, the basic EM signature will be presented along with an analysis of temperature and humidity effects.

Aerogel to simulate delamination and porosity defects in carbon-fiber reinforced polymer composites

Representative defect standards are essential for the validation and calibration of new and existing inspection techniques. However, commonly used methods of simulating delaminations in carbon-fiber reinforced polymer (CFRP) composites do not accurately represent the behavior of the real-world defects for several widely-used NDE techniques. For instance, it is common practice to create a delamination standard by inserting Polytetrafluoroethylene (PTFE) in between ply layers. However, PTFE can transmit more ultrasonic energy than actual delaminations, leading to an unrealistic representation of the defect inspection. PTFE can also deform/wrinkle during the curing process and has a thermal effusivity two orders of magnitude higher than air (almost equal to that of a CFRP). It is therefore not effective in simulating a delamination for thermography. Currently there is also no standard practice for producing or representing a known porosity in composites. This paper presents a novel method of creating delamination and porosity standards using aerogel. Insertion of thin sheets of solid aerogel between ply layers during layup is shown to produce air-gap-like delaminations creating realistic ultrasonic and thermographic inspection responses. Furthermore, it is shown that depositing controlled amounts of aerogel powder can represent porosity. Micrograph data verifies the structural integrity of the aerogel through the composite curing process. This paper presents data from multiple NDE methods, including X-ray computed tomography, immersion ultrasound, and flash thermography to the effectiveness of aerogel as a delamination and porosity simulant.Representative defect standards are essential for the validation and calibration of new and existing inspection techniques. However, commonly used methods of simulating delaminations in carbon-fiber reinforced polymer (CFRP) composites do not accurately represent the behavior of the real-world defects for several widely-used NDE techniques. For instance, it is common practice to create a delamination standard by inserting Polytetrafluoroethylene (PTFE) in between ply layers. However, PTFE can transmit more ultrasonic energy than actual delaminations, leading to an unrealistic representation of the defect inspection. PTFE can also deform/wrinkle during the curing process and has a thermal effusivity two orders of magnitude higher than air (almost equal to that of a CFRP). It is therefore not effective in simulating a delamination for thermography. Currently there is also no standard practice for producing or representing a known porosity in composites. This paper presents a novel method of creating delamin...

Fabrication of a Composite Tow-Steered Structure for Air-Launch Vehicle Applications [STUB]

Generation Orbit (GO) is developing the GO Launcher-1 (GO-1), a single stage liquid rocket that is launched from a Gulfstream III carrier aircraft platform. The vehicle is designed as the next generation platform for hypersonic flight testing and suborbital microgravity research. To reduce mass and increase payload, GO partnered with NASA Langley Research Center to design, analyze, optimize, and fabricate a tow-steered manufacturing development unit of a cylindrical section of a liquid oxygen tank. The fabrication process of using the ISAAC (Integrated Structural Assembly of Advanced Composites) system is described. The structural design challenges and the concept design solutions are also presented to provide the context for the fabrication process. The in-situ nondestructive evaluation supporting the effort is also described.

The effect of in-plane and out-of-plane fiber waviness on guided waves

In-plane (IP) and out-of-plane (OOP) fiber waviness (sometimes referred to as marcelling and wrinkling, respectively) can occur in composite parts as a result of uneven thermal loading during curing, challenges in manufacturing complex geometry parts or other manufacturing variabilities. The changes in fiber orientations due to waviness can have an impact on the intended strength of the composite part and can create stress concentrations that reduce the overall life of the part. These defects can be difficult to detect in cured parts using traditional ultrasonic approaches.

Simulation of guided wave interaction with in-plane fiber waviness

Reducing the timeline for certification of composite materials and enabling the expanded use of advanced composite materials for aerospace applications are two primary goals of NASA’s Advanced Composites Project (ACP). A key a technical challenge area for accomplishing these goals is the development of rapid composite inspection methods with improved defect characterization capabilities. Ongoing work at NASA Langley is focused on expanding ultrasonic simulation capabilities for composite materials. Simulation tools can be used to guide the development of optimal inspection methods. Custom code based on elastodynamic finite integration technique is currently being developed and implemented to study ultrasonic wave interaction with manufacturing defects, such as in-plane fiber waviness (marcelling). This paper describes details of validation comparisons performed to enable simulation of guided wave propagation in composites containing fiber waviness. Simulation results for guided wave interaction with in-pl...

Surface acoustic wave vibration sensors for measuring aircraft flutter

Under NASAs Advanced Air Vehicles Program the Advanced Air Transport Technology (AATT) Project is investigating flutter effects on aeroelastic wings. To support that work a new method for measuring vibrations due to flutter has been developed. The method employs low power Surface Acoustic Wave (SAW) sensors. To demonstrate the ability of the SAW sensor to detect flutter vibrations the sensors were attached to a Carbon fiber-reinforced polymer (CFRP) composite panel which was vibrated at six frequencies from 1Hz to 50Hz. The SAW data was compared to accelerometer data and was found to resemble sine waves and match each other closely. The SAW module design and results from the tests are presented here.