.ME_KSC ENGINEERINGAND TECHNOLOGY

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Spacecraft Pre-launch/Turnaround NDE needs at theKennedy Space Center

Rick Russell

NASA Materials Science Division

In~Space Non-Destructive Inspection Technology Workshop

March 1, 2012

Houston, TX

https://ntrs.nasa.gov/search.jsp?R=20120003446 2018-06-24T05:32:11+00:00Z

NASA RoadmapsKSC ENGINEERING~ANO TECHNOLOGY

NDE included •In

Sp~ce Technology Roadmaps STR • TABSTECHNOLOGY AREA BREAKDOWN STRUCTURE

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CROSS-CUmNGNonde trucci....e Evaluation r Sensors~1odd-BascdCertification &Sustainment MethodLoad and En....."ironmcnts

A12 ·MATERIALS, STRUC­TURES, ECHANICAl

SYSTEMS & MANUFACTURING

Table 22. WBS # 2.5.1 NDETECHNOLOGY PRODUCT Wh.'11 tn.bl.., (unoi'll TRll'Slat us Slop, I. TRl611:0' Tochnolog1'Ch.llongo•

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Excerpt from the NESC Presentation on the "Stateof the NASA..

~~g 'j.'~8h/Xf5tl!./~f, Nondestructive Evaluation (NDE) Discipline" *

• NDE expertise in high demand across all NASA missions- Challenge to provide sufficient expertise- Multi-Center cooperation key

• e.g. NESC NDE TDT, NASA NDE Working Group (NNWG), OrbiterNDE Working Group (ONWG)

- Reduced research capabilities and output lead to risk in meetingfuture mission requirements

• Many mature NDE technologies - challenge applying them to complexaerospace materials and structures- Composites, ceramics, TPS, multilayer, multi-functional structures,

etc.

• Interaction with other disciplines (materials, structures, etc.) presentchallenges

- NDE requirements, expectations, and need to consider NDE in theinitial design

• Structural Health Monitoring (SHM) is new frontier with great potentialreturns- Critical for longer duration manned space missions

KSC NDE Vital to Overall NASA NDEKSC ENGINEERING'" M -I SS-IonAND TECHNOLOGY

• KSC NDE required to maintain KSC/CCAFSinstitutional facility

• KSC NDE required to support current customers(customers defined later slide)

• KSC NDE will be required for future customers- Beginning with Shuttle Program KSC has historical

worked with operations centers (JSC, MSFC) andResearch Centers (LaRC, GRC) to develop andimplement advanced NDE procedures.

- Current and future and NASA programs are dependantof KSC to maintain its current core and advancedcapabilities

KSC ENGINEERINGANO TECHNOLOGY

Where we are now: KSC NDELaboratories

• Institutional (ISC) NDE Primary Services

Provide Non-Destructive Testing andEvaluation for the Kennedy Space Center/AirForce Operational Programs and Facilities

• Examples include- Crane hooks

- Lifting fixtures

- Pressure vessels

• Includes operational ground supportequipment and flight vehicle hardware.

• Provides 24/7 support launch siteoperations customers processing andlaunching rockets and payloads.

• The Lab also develops new NDEtechniques and equipment to improveevaluation capabilities.

• USA/Hangar N NDE Primary Services

Provide Non-Destructive Testing and Evaluationfor the Space Shuttle and other KSC OperationalPrograms

• Performs inspections in support ofspace operations and maintenance ofmulti-purpose space systems

• Provides NDE Project Engineering forNew Technology Development

• Includes advanced NDE capabilities

• Flash Infrared Thermography(Orbiter Wing Leading Edge)

• Terahertz (External Tank)

• Backscatter x-ray (External Tank)Provide R&D collaboration with the NASAEngineering Safety Center (NESC) NDETechnical Development Team

Institutional (ISC) Non-DestructiveExamination Laboratory

KSC ENGINEERING ....AND TECHNOLOGY

• Skills and Capabilities- Eddy Current Testing

Infrared imaging

Leak Testing

Micro-Focus X-Ray

Magnetic Particle

Fluorescent Dye Penetrant

Radiography

High Energy X-Ray - 420 kV

- Portable X-Ray and GammaSources

- Computed Tomography (CT)

- Ultrasonic Testing

- Visual

- Certified Weld Inspection (CWI)

- ASNT-certified Level III engineeringconsulting

JC ..~~_ 1".'"" Me.:oJ .-

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Shuttle External Tank FoamShearography Inspection

1Il:17.111 .!!J"".!lf71'1T ..J~.:JI'~.",..,

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USA/Hangar N Non-Destructive ExaminationLaboratory

poo-r-,,- .-_ _ JRadiography

CT

Film and Digital

Laminography

Ultrasonic

A-Scan, B-Scan, P-Scan

3D CAD UT Modeling

Flash Thermography imaging

Shearography - Vacuum/Acoustic

Magnetic Particle

Fluorescent Dye Penetrant

Visual

CWI, Dimensional, UV Borescope

Eddy Current

MWM, Single/Multi Channel

Bolt Hole/Surface

Custom Coil

Terahertz

Large scale X-Ray Chamber

ll-Axis Robot and gantry

Structural Health Monitoring (IVHM)

Skills and Capabilities

KSC ENGINEERINGAND TECHNOLOGY

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..KSC ENGINEERINGAND TECHNOLOGY

Materials Science Division Support

• Materials & Processes Engineering- Program support (engineering/project management)

- ESD Composites for Exploration

- OCT Composites Cryotank

- R&D

• Applied Physics Lab- Program support (applied R&D)

- R&D

• NASA NOE Working Group (NNWG)

• NESC NOE TOT

KSC ENGINEERINGANO TECHNOLOGY

Example of Past Projects

Device for making detailed maps oforbiter window defects

Ultrasonic leak locator

Prototype device to indicate H2leakage or fire at a flanged joint.

KSC ENGINEERING'"AND TECHNOLOGY

Current/Future NDE Customers

• KSC/CCAFS Institution- e.g. Pad modifications, cyrotanks, crawler

transporter, pressure vessels

• Launch Services Program (LSP)

• 21st Century Launch Program- Orion MPCV

- SLS

• Commercial Cargo

• Commercial Crew

21St Century Launch Complex

• Modernizing the KSCand CCFAS

- Launch architecture

- Environmental

- Payload Processing

- Range Capabilities

- Partnering with AirForce, State ofFlorida and the FAA

--KSC ENGINEERINGAND TECHNOLOGY

~KSC ENGINEERINGAND TECHNOLOGY

Orion MPCV and SLS

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_ Commercial Crew - Blue OriginKSC ENGINEERINGAND TECHNOLOGY

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• Developing a Crew TransportationSystem comprised of a SpaceVehicle (SV) which will be launchedfirst on an Atlas V and then on BlueOrigin's own Reusable BoosterSystem (RBS)

• Capable of carrying 7 astronautsand will transfer NASA crew andcargo to and from the ISS, serve asan ISS emergency escape vehicle forup to210 days, and perform a.landlanding to minimize the costs ofrecovery and reuse.

KSC ENGINEERING~AND TECHNOLOGY

Commercial Crew - Boeing

• Developing a IIfull service" systemfor both NASA and commercialcustomers to LEO destinations.

• CST-lOa spacecraft is configured tocarry up to 7 crew members and/orcargo to LEO destinations includingISS and SA Sundancer spacecomplex

• Compatible with multiple launchvehicles

• Designed for land landings and canbe reused for up to 10 missions

r------ _Spacecraft S~ent

CST-100

~~...----Crew Module (CM)

~--- Service Mowle (SM)

Operations Segment "'----=--0

• Crew Training• cargo Integration• Mission Plann"ng• ssion Operations• landing and Recovery• Assembly Integrationand es Facility

• Mission Operations Center• Network services• Landing Site Facilities• Ti "ng Systems

Commercial Crew - Sierra NevadaKSC ENGINEERING~AND TECHNOLOGY

• Developing the Dream ChaserSpace System (DCSS).

• Provides LEO access to the ISSand commercial customersneeding suborbital services

• Third generation design derivedfrom extensive NASA Langleyresearch providing a reusable,pressurized, lifting-body vehiclethat lands on a conventionalrunway.

• Will most likely utilize an Atlas Vlaunch vehicle

~KSC ENGINEERINGAND TECHNOLOGY

Commercial Crew - SpaceX

• SpaceX's Dragon crew vehiclewas the first commercialspacecraft to return from orbit

• Maturation of theFalcon9/Dragon transportationsystem with a particular focus ondeveloping an integrated LaunchAbort System.

• Developing prototypes of the.crew cabin, crew seats and ..........---_;;:restraints, crew control panel ~......and life support system.

KSC ENGINEERINGANO TECHNOLOGY

50 what are K5C's needs?

• The basic infrastructure of NDE support will remain but at areduced capacity, especially in advanced NDE development- Consolidation is still in work

• The new NASA programs and the new commercialcustomers do not have the "deep pockets" that the ShuttleProgram had- The challenge for KSC is to maintain a world class NDE

organization with less resources

• The NASA Materials Science Division will remain the poefor NDE operations and advance NDE development- Key challenge is to forecast future customer needs- Examples of a few recent development efforts are on the

following charts

...KSC ENGINEERINGAND TECHNOLOGY

Multifunctional Hybrid CompositeMetamaterial Systems

• Inspection of damage and subsequent repairs on composite structureswhich will involve:

• Develop a Surface Wave propagating (SWP) structure consisting of arrayed sensors(piezoelectric), in conjunction with a passive single chip RadiofrequencyIdentification (RFID) strain/accelerometer/temp sensor configuration.

• The goal will be to simultaneously transfer power/ and communicate via a wireless network/ inorder to detect damage and induce or monitor the cure of a repair in a fiber reinforcedcomposite part.

• Validation of the tools using current NDI/NDE methods

• Repair of materials for primary structures (including newly developed outof autoclave material designed for use on primary structures).

• Cradle-to-grave monitoring of the repair including monitoring repair cure, the initialquality of repair during installation and continuing the monitoring throughout itslifetime.

• Provide cost-cutting measures for repair of out-of-autoclave composite structuresfor primary structures through the development of standard repair and monitoringkits

Cross-section view

~KSC ENGINEERINGAND TECHNOLOGY

Eddy Current Stress Gages for COPVHealth Monitoring

• Utilizes MWM® Technology

- Goal is to provide a means of directly measuringthe stresses at various depths in the overwrap

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Frequency (Hz)

scanDireetlon

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~KSC ENGINEERINGANO TECHNOLOGY

Eddy Current Stress Gages for COPVHealth Monitoring

Magnitude vs. Set (Average of all Channels)

252010 15Pressurization Interval

5

17° Sensor Orientation60° Sensor Orientation90° Sensor Orientation

1.01

1.005

0.995

s- n

Wire Detection Systems & Integratio

l)amllged

~KSC ENGINEERINGAND TECHNOLOGY

Wire ConstructionMaterials examined during development of detection layer

• Metal foils CSlonfig&lntion

• Nickel coated carbon fiber• Conductive carbon cloth• Metallized mylar tapes• Sputter coated metals• Electroplated metals• Printed-on conductive inks• Inherently conductive polymers

Cross section of RG316 wire withCu foil and PTFE jacket

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Extruded FEPTape wrappedDamage profile for TDR testing