Robert F. Anastasi

Terahertz NDE for Under Paint Corrosion Detection and Evaluation

Corrosion under paint is not visible until it has caused paint to blister, crack, or chip. If corrosion is allowed to continue then structural problems may develop. Identifying corrosion before it becomes visible would minimize repairs and costs and potential structural problems. Terahertz NDE imaging under paint for corrosion is being examined as a method to inspect for corrosion by examining the terahertz response to paint thickness and to surface roughness.

Investigation of Fiber Waviness in a Thick Glass Composite Beam Using THz NDE

Fiber waviness in laminated composite material is introduced during manufacture because of uneven curing, resin shrinkage, or ply buckling caused by bending the composite lay-up into its final shape prior to curing. The resulting waviness has a detrimental effect on mechanical properties, therefore this condition is important to detect and characterize. Ultrasonic characterization methods are difficult to interpret because elastic wave propagation is highly dependent on ply orientation and material stresses. By comparison, the pulsed terahertz response of the composite is shown to provide clear indications of the fiber waviness. Pulsed Terahertz NDE is an electromagnetic inspection method that operates in the frequency range between 300 GHz and 3 THz. Its propagation is influenced by refractive index variations and interfaces. This work applies pulsed Terahertz NDE to the inspection of a thick composite beam with fiber waviness. The sample is a laminated glass composite material approximately 15mm thick with a 90-degree bend. Terahertz response from the planar section, away from the bend, is indicative of a homogeneous material with no major reflections from internal plies, while the multiple reflections at the bend area correspond to the fiber waviness. Results of these measurements are presented for the planar and bend areas.

Terahertz NDE application for corrosion detection and evaluation under shuttle tiles

Pulsed Terahertz NDE is being examined as a method to inspect for possible corrosion under Space Shuttle Tiles. Other methods such as ultrasonics, infrared, eddy current and microwave technologies have demonstrable shortcomings for tile NDE. This work applies Terahertz NDE, in the frequency range between 50 GHz and 1 THz, for the inspection of manufactured corrosion samples. The samples consist of induced corrosion spots that range in diameter (2.54 to 15.2 mm) and depth (0.036 to 0.787 mm) in an aluminum substrate material covered with tiles. Results of these measurements are presented for known corrosion flaws both covered and uncovered and for blind tests with unknown corrosion flaws covered with attached tiles. The Terahertz NDE system is shown to detect all artificially manufactured corrosion regions under a Shuttle tile with a depth greater than 0.13 mm.

The Potential for Imaging In-Situ Damage in Inflatable Space Structures

NASA is investigating the use of inflatable habitat structures for orbital transfer and planetary applications. Since space structures are vulnerable to damage from micrometeoroid and orbital debris, it is important to investigate means of detecting such damage. This study is an investigation into methods for performing non‐destructive evaluation (NDE) on inflatable habitat modules. Results of this work showed that various electromagnetic imaging modalities from microwaves to terahertz imaging have the greatest potential for a viable, portable, NDE tool which could possibly be deployed aboard an inflatable habitat module.

Application of Terahertz Radiation to the Detection of Corrosion under the Shuttle's Thermal Protection System

There is currently no method for detecting corrosion under Shuttle tiles except for the expensive process of tile removal and replacement; hence NASA is investigating new NDE methods for detecting hidden corrosion. Time domain terahertz radiation has been applied to corrosion detection under tiles in samples ranging from small lab samples to a Shuttle with positive results. Terahertz imaging methods have been able to detect corrosion at thicknesses of 5 mils or greater under 1” thick Shuttle tiles and 7‐12 mils or greater under 2” thick Shuttle tiles.

Study of Generation Mechanisms for Laser Ultrasonics

The aerospace industry is beginning to use advanced composite materials for primary load bearing structures and their failure mechanisms must be better understood to predict their behavior in service. The Combined Loads Tests (COLTS) facility is being constructed at the NASA Langley Research Center to characterize these failure mechanisms. Laser based ultrasonic NDE can monitor the samples during dynamic loading without interfering with the structural tests. However, the constraints of implementing laser ultrasound in a structures laboratory reduces the efficiency of the technique. The system has to be “eye-safe” because many people will be present during the structural tests. Consequently, laser light has to be delivered through fiber optics and a significant amount of light is lost. Also, the nature of the composite materials makes laser ultrasonic inspection difficult. The composites of interest are formed from woven layers that are stitched through the laminate thickness and bound in a resin matrix. These materials attenuate ultrasound strongly and exhibit a high degree of scattering. In this paper, we describe a field-deployable laser based ultrasonic NDE system that we developed to investigate structures during testing in the COLTS facility. We illustrate the design constraints that reduced efficiency and present some ultrasonic data from thick stitched composites.

Comparison of Ultrasound with Tensile Testing of Thermally Damaged Polyimide Insulated Wiring (MIL‐W‐81381)

Ultrasonic measurements were performed on MIL‐W‐81381/7, /12, and /21 wire, a polyimide (Kapton®) insulated wire. The phase velocity for the 20‐gauge MIL‐W‐81381/7 wire had a baseline value of 3023 ± 78 m/s. After exposure to high temperatures, the wire’s phase velocity rapidly increased, and reached an asymptotic value of 3598 ± 20 m/s after 100 hours exposure. Similar responses were measured in other gauges. The baseline measurements of Young’s moduli resulted in values of 5636 ± 486, 7714 ± 505, and 8767 ± 292 KSI for the 20 ga, 16 ga, and 12 ga. wires respectively.