Presentation to AIAA in Albuquerque, NM

2. Overview
• Quick overview of JSC-WSTF
• Interesting Projects I have done and a reflection
on the Shuttle Program
• Nondestructive Evaluation (NDE) and related
Structural Health Monitoring
2

3. 3

4. Orbiter and transport over the WSTF 300 area
4

5. Unique Capabilities
Simulated altitude testing of full-scale integrated hypergolic
propulsion systems
Large-scale explosion testing of hypergolic, cryogenic, Solid,
and most new “green” propellants
Component testing in high temp/high flow gaseous oxygen and
hydrogen
Repair depot for components in the toxic hypergolic propellant,
oxygen, and hydrogen systems aboard Shuttle and ISS
White Sands Space Harbor (WSSH) Flight tests
Agency facility for hypervelocity impact testing, including
accommodations for hazardous targets
Capability for all materials testing defined by NASA Standard
6001 (NHB 8060.1C)
Design and hazards analysis of oxygen and hydrogen systems
5

6. WSTF Propulsion Test Activities
Eight engine/system test
stands (5 vacuum cells)
Long-duration high-
altitude simulation
Hypergolic and cryogenic
liquid rocket systems
Flight component repair
and refurbishment
Rocket Engine Firing Inside Flushing Primary RCS thruster
Vacuum Test Cell propellant valve
Propulsion Test Area 400 Altitude Simulation System Operation for Rocket
Engine Tests

7. WSTF Laboratories Test Activities
• NHB 8060.1 Testing • Oxygen Hazards Assessment
• Propellant Characterization • Ignition & Combustion Testing
• Material Compatibility • Component Development, Acceptance & Qualification
Propellant & Explosion Hazards Assessment Hypervelocity Impact Testing

8. Molecular Analysis of Surface Effects Using X-ray
Photoelectron Spectroscopy Instrument
Other X-ray:
• SEM EDAX
• CT (up to 450 KV)
8

9. Hypervelocity and Low Velocity Impact Test
Facilities
Shuttle Window Pit
Caused by Paint Chip
.07, .17, .30, .50, and 1 caliber two-stage light
gas guns capable of propelling 0.25 to 22 mm 9
projectiles in excess of 7.0 km/s (16,000 mi/h)

10. WSTF Nondestructive Evaluation Capability
Traditional:
• Thermography: pressurized, flash, heat soak and through transmission
• HD Shearography: pressurized, thermal excitation
• Radiography
• X-ray CT: metals and composites
• Ultrasound: A-scan, B-Scan, C-scan, thickness measurement
• Handheld eddy current probes and bolt scanner
• Certified visual inspection and training classes
New Methods
• Laser profilometry: scanning of Composite overwrapped pressure vessels (COPVs)
• Eddy current: scanning of COPV liner (inside and out)
• Raman Spectroscopy (strain and stress rupture progression)
Structural Health Monitoring
• Matrix ultrasonic senses (i.e., Acellent and Metis)
• Acoustic Emission: Acceptance testing, Damage detection and failure prediction
• Surface and embedded Fiber optic health monitoring: strain, acoustic, shape sensing
10

11. NNWG.org
11

12. 12

13. Shearography NDT System Schematic Diagram
Shearography
Image Calibration Laser : Narrow Line,
Variable Diffusion
Device/Data Beam Test Part
(Honeycomb
Panel Shown)
CCD
Computer & Camera
Imaging Software
Phase
Stepper
P1
Phase Stepper
Controller
P2
Beam
Phase Splitter
Shift
Monitor Mirror 2 Axis
Tilt
Images & Test Part Mirror
Data Stress
Controller & Disbond
Sensors Skin to Core
Vacuum Thermal Test Part
Vibration
Stress Device
(Thermal Shown)

14. Shearography Test Results By Stress Method
Thermal Shearography
Aluminum Honeycomb Panel
Pressure Shearography
COPV
Vacuum Shearography
Composite/Nomex Honeycomb
Acoustic Shearography
Foam Cryogenic Fuel Tank TPS

15. Carbon Fiber/Nomex Core Shearography NDT Std.
• Double/Single Teflon Inserts
• Milled Flat Bottom Holes
• Representative Foreign Material in composite layers
0.25 0.5 0.875 1.5 inches
0.08 Delamination

16. 25 Ply Carbon Fiber Laminate Panel With Teflon Insert
• Well consolidated
Carbon fiber laminate
• Round Teflon Insert
is seen with Thermal
shearography.
• Smaller disbond seen
on top of insert.

17. High Definition Shearography
• The LTI-5100HD Advanced
Shearography System, equipped with
a TES-200 thermal excitation unit, has
greatly improved the ability to baseline
the received stress state and monitor
and identify visually undetectable
subsurface impact damage.
– The need is to correlate damage to
response and do POD studies
– Physical defect standards help
Composite overwrapped pressure vessel
17 Pressure shearograph of COPV impacts inspection (top) and thermal shearograph of a
delivered using a 0.5 in. ball-end tup vessel with delaminations and a void (bottom)

18. “Smart COPV”
Integrated COPV Structural Health
Monitoring (SHM) Systems That Target
Space Exploration and ISS Needs

19. Background Cont’d
• Future NASA missions may not be successful without SHM (ref. OCT
Roadmaps)
• Potential near-term needs include carbon-epoxy (C/Ep) COPVs used
on ISS, ISS Nitrogen-Oxygen Recharge System (NORS) if reused, the
Orion crew and service modules, and as nearly all future long duration
NASA spacecraft missions
– Incidental but direct benefits also exist for COPVs used in DOT liquid natural gas
and hydrogen storage applications
– Other composite structures of interest are load bearing, fracture critical composite
materials used in DoD, commercial aerospace and NASA applications (the latter
include composite structures being developed under NASA„s Composites for
Exploration program plus several precursor programs (i.e., LSSM, both wet and dry
structures), especially where cyclic loading is experienced
Nitrogen Tank Assembly 19
High Pressure Gas Tank - Oxygen
(45”L×19.7”D)
HPGT COPV (37.89”D)

20. GRC AE Analysis Applet LaRC DIDS AE DFRC FBG strain measurement
WSTF FR Analysis Tool KSC MSG stress measurement
Smart COPV
WSTF/LaRC Eddy
MSFC FOAE
Current &
Profilometry FBGs
AE
AE waveform analysis
Las Gatos COPV Results
WSTF COPV burst prediction

21. Project Details by Center
21

22. WSTF COPV Profilometry and Eddy Current Scanners
Sensor Linear Stage
Upper Vessel
Positioning Stage
Calibration
Fixture
Vessel Plug
Centering Guide
Lower Vessel External Eddy Current (EC)
Positioning Stage
External Profilometer added to Probe added
Original Scanner
Figure 1 – WSTF Cylindrical COPV Mapping System
Original Internal Profilometer
12-foot Orion Internal
Profilometer developed and
verified on simulator vessel
7-foot NORS Internal
Profilometer developed, verified
and actively being used by the
Articulated sensor developed to ISS NORS Program 22
X-Y Coupon Scanner inspect COPV domes in NORS
developed Internal Profilometer

23. Second Generation Laser Profilometry
Delivery shaft
Outrigger arms
Laser exit port
Laser receiving port
23
Articulated sensor allows scanning of Ellipsoidal ends

24. Laser Profilometry of COPV interior surface quantifies liner
buckling which is difficult to inspect by other methods
Calibration traceable to National Standard and demonstrated better than 24
0.001 accuracy/repeatability on 26-in and better than 0.002 accuracy/
repeatability on 40-in

25. NESC Assisting with Internal EC Scanner Being
Developed (shown deployed)
Collapsible internal EC probe deployed for scans
(conceptual design)
25
Internal EC probe shown interfaced to existing
laboratory stage

26. Scans of NNWG Vessel following Stress
Rupture testing
Internal (left) and external (right) radial scans of the same vessel.
26

27. WSTF: Automated AE for COPV Pass/Fail
Goal: Develop acoustic emission SHM hardware for ISS Felicity Ratio Analysis Tool (FRAT)
• Automate FFT batch processing
• Implement AE pattern recognition
• Promulgate consensus pass/fail criteria for COPVs
Approach: Statistical Physics vs. Stochastic model used
• Determine „in-family‟ behavior of well-characterized specimens/test articles
• Predict behavior of unknown based on population response
• Tailor method to actual in-service pressure schedules
Status: In-house software & AE methods developed
• FR analysis software developed
– Statistical methods developed
– Application of above methods to COPVs demonstrated
– EWMA „knee‟ method developed (excellent preliminary results)
• Data acquisition parameters optimized C/Ep Comparative Damage
Tolerance
• Response surfaces for C/Ep materials-of-construction generated 1.3 1.3
• Burst pressure for a COPV predicted 1.2 1.2
Felicity Ratio
1.1 1.1
Burst Prediction for
COPVs 1.0 1.0
0.9 T1000 carbon/epoxy tow 0.9
IM-7 carbon/epoxy tow
Kevlar 49/epoxy tow
C/Ep Strand Testing 0.8
IM-7 carbon/epoxy COPV
0.8
0.0 0.2 0.4 0.6 0.8 1.0
27
Load Ratio

28. GRC: Acoustic Emission Analysis Applet
Goal: New Input FY12
• Develop an Acoustic Emission Analysis
Applet to produce a „Smart‟ real-time
analysis capability to support NASA
missions
Approach:
• Use consensus AE waveform
characterization
parameters, e.g., amplitude, counts, rise
time, duration, centroid and peak
frequencies, etc., to differentiate
composite damage event
Status:
Acoustic Emission Analysis Applet derived
•
from AEAA software:data set size
Rewrote for UNLIMITED
• All events available for viewing in Applet
using slider control
• Translator from .WAVE  NDF
incorporated into Applet
• Can subset and threshold events for
analysis
• Time/Event File generated
• AE Statistics vs. Time generated/saved to
spreadsheet file
• User Manual written
• Currently being beta-tested by WSTF 28

29. LaRC - Application of DIDS Hardware to COPVs
Goal:
• Demonstrate the ability of flight certified hardware to
perform AE measurements in COPVs
Approach:
• Evaluate the ability of the Distributed Impact Detection DIDS system with sensors and
System (DIDS) to capture AE events during testing short cables
• Evaluate system‟s throughput vs. the requirements of a
measuring a COPV
• Assess the DIDS‟ ability to function as an IVHM system
Status:
• DIDS hardware has been certified for on-orbit
application and is currently on orbit, being used to
support the SDTO project UBNT
DIDS system installed
behind rack in Node 2 29

30. MSFC: Smart Layer for Smart COPV
Goals:
Define Critical Damage Accumulation (CDA) in Composite Overwrap
Pressure Vessel (COPV) before stress rupture occurs and corroborate FBG
(CDA) with a know NDE inspection standard: AE Felicity ratio; s
Additional, damage severity and location is desired.
Approach:
1. Perform cycle testing of COPV until Keizer effect is violated.
COPV integrated
At reduced loading, damage index will be measured.
Smart layers
2. Leverage funding from OCT and Composite for Exploration
Status: Impacts on sandwich
1. Tested composite laminate with foam core. foam. Damage was
2. Currently have three 18‟” COPV that will be located and quantified
tested at MSFC and possibly one at WSTF. by Acellent Smart
Patch.

31. DFRC: Embedded Fiber Bragg Gratings
Objectives
• Perform real-time in-situ structural monitoring of COPVs by
acquiring 100s of fiber Bragg grating measurements from sensors
Theoretical
embedded within the composite structure of the COPV
development
• Develop analytical and experimental methods to reliably interpret Coupon testing
strain measurements from embedded FBG sensors
• Develop a robust “early-warning” indicator of COPV catastrophic
failure
Approach
• Analytically model the embedded FBG sensors Analysis and Modeling
• Attach 100s of FBG sensors to outer COPV surface
• Conduct baseline testing of surface FBGs
• Overwrap bottle (surface FBGs become embedded)
• Instrument new sensors on new outer surface
• Test to failure; correlate data at each step
Status:
• Hypercomp COPV Testing Complete Sensor Installation
• Instrumented COPV with 1600 FBGs (800
embedded and 800 surface mounted)
• GD T1000 Bottle – Surface sensor testing complete
• Bottle being overwrapped this week (4/27)
• Final burst tests planned for June 2012 at WSTF
Embedding / Fabrication Failure Testing 31

32. KSC: Magnetic Stress Gages (MSGs)
Project Objectives
• Design and demonstrate the ability of NDE sensors to measure
stresses on the inner diameter of a COPV overwrap.
• Results will be correlated with other NDE technologies such as
acoustic emission (AE)
• Project will build upon a proof-of-concept study performed at KSC
which demonstrated the ability of MSGs to measure stresses at
internal overwraps and upon current AE research being performed
at WSTF
• Ultimate goal is to utilize this technology as a key element of health
monitoring under the “Smart COPV” Program
– Applicable to essentially all future flight programs
32

33. KSC: Proof of Concept Hydrostatic Test
• Full COPV tested hydrostatically at KSC on February 5, 2011
• Vessel cycled to 8,000 psi and back to zero stopping at 2,000 psi increments
– Pressure chosen to mimic MEOP
– Estimated design burst pressure of COPV is 16,000 psi
• Based on coupon tests 3 sensor configurations were chosen
– Different wavelength to obtain various depth of penetration
• Tests were performed with 3 sensor orientations
– 90º, 60º and 17º to align sensor drive with fiber orientations
33

34. Backup Slides
34

35. Example AE Results
S/N 82 FAILURE.xls 21 December 2006
1800
1600 RUPTURE TIME: 91 hrs
Number of AE Events
1400
1200
1000
800
600
ADVANCE NOTICE: 1.98 hrs
400
200
0
52000 53000 54000 55000 56000 57000 58000 59000 60000
AE indications begin to accumulate well before rupture occurs.
Time (sec)
The synchronization of these data to strain and temperature
indications will be accomplished in the next phase of our project
35

36. Final Week of COPV Test Before Rupture
~6 events / hour
~2 events / hour
36

37. Felicity ratio (FR)
• Felicity ratio (FR) coupled with AE feature
analysis, especially peak frequency and energy, shows
promise as analytical pass/fail criteria
37

38. Results & Discussion
A 6.3-in. diameter IM-7 COPV was subjected to an ILH pressure
schedule at LR ≈ 0.3 to 0.9
Pressure & Events vs. Time
0 to 17500 s 17500 to 37500 s (cont.)
AE due to significant
composite damage
LR
below autofrettage P
= 0.89
Event No. (filtered data)
Event No. (filtered data)
Potential Pass/Fail Criteria
Lower load hold AE
indicative of severe
accumulated damage
same test 38
38
continued

39. Example COPV Test
Potential Pass/Fail Criteria
FR < 1; The true limit is
structurally dependant (0.95-0.99).
Felicity ratio results for an IM7 composite overwrapped pressure vessel
pressurized to 6800 psi and then to burst at 7870 psi
39

40. Results & Discussion
FFT (unfiltered) showing concerted failure using De Groot‟s
frequency ranges
fiber breakage
matrix cracking
pull-out
debonding
40

41. Technique Development
Carbon Stress Rupture Test System
Conventional strain gauges
installed near fiber Bragg
gratings, relative to laser
profilometry map
20 Carbon Vessels and real-time NDE in 41
WSTF Lexan protective enclosure allows
inspection while at test pressure

42. Inspection Challenges
COPVs used on ISS, the Orion Crew/Service Modules, and most other
exploration spacecraft potentially need inspection under various scenarios,
but they are often inaccessible
– If it can be implemented, monitoring may address most needs
– The concept of snakes/endoscopic NDE may help if provisions are made for
in-space inspection or ports can be made
• Explore micro-meteoroid & orbital debris (MMOD) strike site and through to COPV
surface if structure is penetrated
• Must be qualified to work in a space environment if used for EVA
– Imaging of composite through the metal structure and insulation may help if
adequate sensitivity is demonstrated
42

43. Nitrogen Tank Assembly
43

44. Plasma Contactor Unit
44

45. ISS Payloads, Experiments, Systems
Six GBUs in Kibo
AMS
Space DRUMS
45

46. SAFER
SAFER (9”Lx6.6”D)
46

47. Contributing Information
• 4th IAASS Conference - Making Safety Matter , Nondestructive Evaluation and Monitoring Results from
COPV Accelerated Stress Rupture Testing, NASA White Sands Test Facility (WSTF)
(No. 1878627)
• Use of Modal Acoustic Emission to Monitor Damage Progression in Carbon Fiber/Epoxy Tows
and Implications for Composite Structures, ASNT Fall Conference & Quality Testing Show, NASA
NDE II Houston, TX
• New ASTM Standards for Nondestructive Testing of Aerospace Composites, ASNT Fall
Conference & Quality Testing Show, NASA NDE II Houston, TX Jess M. Waller and Regor L.
Saulsberry NASA-JSC White Sands Test Facility
48th AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference,
AIAA-2007-2324 , Overview: Nondestructive Methods and Special Test Instrumentation
Supporting NASA Composite Overwrapped Pressure Vessel (COPV) Assessments
• NDE Methods for Certification and Production/Performance Monitoring of Composite Tanks,
David McColskey, Marvin Hamstad, Regor Saulsberry, Jess Waller
• Shearography NDE of Composite Over-Wrapped Pressure Vessels (COPVs), ASNT Fall
Conference 2007
Survey of Nondestructive Methods Supporting Shuttle and ISS Composite Overwrapped Pressure
Vessel (COPV) Testing, Aging Aircraft Conference , 2006
47

48. Contributing Information
• G.P. Sutton & O. Biblarz, Rocket Propulsion Elements, 7th Ed., John Wiley & Sons, Inc., New
York, 2001, ISBN 0-471-32642-9. 2. D.K. Huzel & D.H. Huang, Modern Engineering for Design of
Liquid-Propellant Rocket Engines, Vol 147, Progress in Astronautics and Aeronautics, Published
by AIAA, Washington DC., 1992, ISBN 1-56347-013-6. 3. V. Yang, T. B. Brill, W.-Z. Ren, Solid
Propellant Chemistry, Combustion, and Motor Interior Ballistics, Published by AIAA, Washington
DC, 2000, ISBN 1-56347-442-5 4. F.-K. Chang, ed., Structural Health Monitoring 2005, DEStech
Publications, 2005, ISBN 1-932078-51-7
48

49. Relevant Literature (non-inclusive list)
1. AIAA
– S-080 Space Systems - Metallic Pressure Vessels, Pressurized Structures, and Pressure Components
– S-081A Space Systems - Composite Overwrapped Pressure Vessels (COPVs)
2. ASME
– STP-PT-021 Non Destructive Testing and Evaluation Methods for Composite Hydrogen Tanks
3. ASTM
– E 1419 Test Method for Examination of Seamless, Gas-Filled, Pressure Vessels Using Acoustic Emission
– E 1736 Practice for Acousto-Ultrasonic Assessment of Filament-Wound Pressure Vessels
– E 2191 Test Method for Examination of Gas-Filled Filament-Wound Composite Pressure Vessels Using
Acoustic Emission
– E 2581 Practice for Shearography of Polymer Matrix Composites, Sandwich Core Materials and Filament-
Wound Pressure Vessels in Aerospace Applications
4. ISO
– 14623 Space Systems - Pressure Vessels and Pressurized Structures - Design and Operation (similar to
AIAA S-080 and -081, and NASA-STD-5009)
5. NASA
– MSFC-RQMT-3479 Fracture Control Requirements for Composite and Bonded Vehicle and Payload
Structures
– NASA-STD-5007 General Fracture Control Requirements for Manned Spaceflight Systems
– NASA-STD-5009 Nondestructive Evaluation Requirements For Fracture Control Programs
• JSC Special Addendum Physical Crack Standard
– NASA-STD-5019 Fracture Control Requirements for Spaceflight Hardware
– NASA-STG-5014 Nondestructive Evaluation (NDE) Implementation Handbook for Fracture Control
Programs (draft)
6. Miscellaneous
– AFSPCMAN 91-710
– CSA NGV2-2000 Basic Requirements for Compressed Natural Gas Vehicle (NGV) Fuel Containers
– KHB 1710.2D
– MIL-STD-1522 Standard General Requirements for Safe Design and Operation of Pressurized Missile 49
and Space Systems

50. Background – ASTM E07.10 TG of NDE
of Aerospace Composites
• In late 2004, NASA took the lead in initiating efforts to develop
national voluntary consensus standards for NDE of aerospace
composite materials, components and structures
• ASTM Task Group (TG) for NDE of Aerospace Composites formed
in January 2005 (under ASTM E07.10)
• The TG has been meeting twice a year since formation:
– currently comprised of 116 members
– chaired by George Matzkanin from TRI/Austin
– other principals include Jess Waller and Regor Saulsberry, NASA-JSC White
Sands Test Facility; and Tom Yolken, TRI/Austin
• Initial focus was on polymer matrix composite material with relatively
simple geometries such as flat panel laminates
• Current focus is on composite components with more complex
inspection geometries, specifically COPVs
– metallic liner (WK 29068)
– composite overwrap (WK 29034)
– liner/overwrap interface
50
– Guide (TBD)

51. Background – ASTM Standards Developed
Since 2005 and Current Plan
2005
2010 NDE of Flat Panel Composite Standard Practices and Guide
2011
5-year re-approval
2012 of E2580, E2580 and E2581
2013 NDE of COPV Standard Practices, Feasibility of NDE of COPV Guide
51

52. 52

53. 53

54. PRCS Thruster Injector Crack NDE

55. Composite Thickness Measurement
55
Eddy Current System for Real-time COPV Composite Thickness

56. Pre Burst NDE
Epoxy run
Black spots are
bad pixels from
imager
Void Indications
Thermography Image
56