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Void nucleation, growth, and coalescence in A356 aluminum notch specimens was determined from a combination of experiments, finite element analysis, nondestructive analysis, and image analysis. Notch Bridgman tension experiments were performed on specimens to failure and then other specimens were tested to 90%, 95%, and 98% of the failure load. The specimens were evaluated with nondestructive X-ray tomography and optical image analysis. Finite element simulations of the notch tests were performed with an elastic–plastic internal state variable material model that incorporated the pertinent microstructures (silicon particle volume fraction and size distribution and porosity volume fraction and size distribution). Parametric finite element simulations were performed to give insight into various initial conditions and responses of the notch tensile bars. The various methods all corroborated the same damage progression.

An x-ray tomography system is being developed for high resolution inspection of large objects. The goal is to achieve 25 micron resolution over object sizes that are tens of centimeters in extent. Typical objects will be metal in composition and therefore high energy, few MeV x-rays will be required. A proof-of-principle system with a limited field of view has been developed. Preliminary results are presented.

As a result of an arms reduction treaty between the United States and the Russian Federation, both countries will each be storing over 40,000 containers of plutonium. To help detect any deterioration of the containers and prevent leakage, we are designing a digital radiography and computed tomography system capable of handling this volume reliably, efficiently, and at a lower cost.

Real-time radiography was successfully applied to the Titan-IV Solid Rocket Motor Upgrade (SRMU) static firing test QM-2 conducted February 22, 1993 at Phillips Laboratory, Edwards AFB, CA. The real-time video data obtained in this test gave the first incontrovertible evidence that the molten slag pool is low (less than 5 to 6 inches in depth referenced to the bottom of the aft dome cavity) before T + 55 seconds, builds fairly linearly from this point in time reaching a quasi-equilibrium depth of 16 to 17 inches at about T + 97 seconds, which is well below the top of the vectored nozzle, and maintains that level until T + 125 near the end motor burn. From T + 125 seconds to motor burn-out at T + 140 seconds the slag pool builds to a maximum depth of about 20 to 21 inches, still well below the top of the nozzle. The molten slag pool was observed to interact with motions of the vectored nozzle, and exhibit slosh and wave mode oscillations. A few slag ejection events were also observed.

We apply dual-band infrared (DBIR) imaging as a dynamic thermal tomography tool for wide area inspection of a Boeing 737 aircraft (owned by the FAA/AANC at the Sandia hangar in Albuquerque, NM) and several Boeing KC-135 aircraft panels (used for the round robin experiment conducted at Tinker AFB, OK). Our analyses are discussed in this report. After flash-heating the aircraft skin, we record synchronized DBIR images every 40 ms, from onset to 8 seconds after the heat flash. We analyze selective DBIR image ratios which enhance surface temperature contrast and remove surface-emissivity clutter (from dirt, dents, tape, markings, ink, sealants, uneven paint, paint stripper, exposed metal and roughness variations). The Boeing 737 and KC-135 aircraft fuselage panels have varying percent thickness losses from corrosion. We established the correlation of percent thickness loss with surface temperature rise (above ambient) for a partially corroded F-18 wing box structure (with a 2.9 mm uncorroded thickness) and several aluminum plates (with 1.0, 1.1, 2.3, and 3.9 mm thicknesses) which had 6 to 60% thickness losses at milled flat-bottom hole sites.© (1993) COPYRIGHT SPIE--The International Society for Optical Engineering. Downloading of the abstract is permitted for personal use only.

We discuss three-dimensional dynamic thermal imaging of structural flaws using dual-band infrared (DBIR) computed tomography. Conventional (single-band) thermal imaging is difficult to interpret. It yields imprecise or qualitative information (e.g., when subsurface flaws produce weak heat flow anomalies masked by surface clutter). We use the DBIR imaging technique to clarify interpretation. We capture the time history of surface temperature difference patterns at the epoxy-glue disbond site of a flash-heated lap joint. This type of flawed structure played a significant role in causing damage to the Aloha Aircraft fuselage on the aged Boeing 737 jetliner. The magnitude of surface-temperature differences versus time for 0.1 mm air layer compared to 0.1 mm glue layer, varies from 0.2 to 1.6 degree(s)C, for simultaneously scanned front and back surfaces. The scans are taken every 42 ms from 0 to 8 s after the heat flash. By ratioing 3 - 5 micrometers and 8 - 12 micrometers DBIR images, we located surface temperature patterns from weak heat flow anomalies at the disbond site and remove the emissivity mask from surface paint of roughness variations. Measurements compare well with calculations based on TOPAX3D, a three-dimensional, finite element computer model. We combine infrared, ultrasound and x-ray imaging methods to study heat transfer, bond quality and material differences associated with the lap joint disbond site.© (1993) COPYRIGHT SPIE--The International Society for Optical Engineering. Downloading of the abstract is permitted for personal use only.

An easy method to measure gamma ray energies to about 0.003 MeV is suggested which utilizes the reaction Q -value, and demands consistency between the sum of the cascade gamma ray energies between two levels and the energy of the direct transition. This procedure is applied to the 0.9363-MeV resonance in the 27 Al(p, γ ) 28 Si reaction.

Performance characteristics have been measured for the Phillips type 56 AVP and type XP 1020 photomultiplier tubes using NaI(Tl) crystals as scintillators. The measurements consisted of recording coincidence-delay curves as a function of gamma-ray energy and photomultiplier high voltage, determining the linearity of pulse height distributions as a function of gamma-ray energy and high voltage, and measuring the gamma-ray energy equivalent of noise pulse as a function of high voltage.

Neutron detectors for flight test applications use either a photomultiplier tube (PMT) or a silicon photodiode as a light detector to monitor the light output of scintillation materials. Silicon diodes lack sensitivity, so PMT's are used in most low flux neutron applications. The SA 1690 is presently the only Sandia qualified PMT. It has a complex temperature response requiring the selection of a temperature compensation circuit during assembly to meet accuracy requirements. Results are presented of a study which was performed to evaluate the temperature stability of two other light detectors and to compare the results with the performance of the SA 1690.

The beta-backscatter method of measuring thin laminates on thick substrates was evaluated for possible production inspection applications of aluminum ion plating on U-0.75 Ti parts. The choice of radiation source, the effects of surface curvature, and background radiation from uranium isotopes were examined. Measurements of aluminum coatings on U-0.75 Ti test coupons and cylindrical parts were made with the ..beta..-backscatter technique and compared to ..cap alpha..-transmission measurements.

The efficiency of a silicon surface-barrier detector with a proton radiator for detecting 14 MeV neutrons was measured as 0.29% using a polyethylene radiator, and 0.34% using a paraffin radiator. Absolute fluence and timing information can be obtained by counting the number and time distribution of pulses from the radiator/surface-barrier detector. Fluence values with an accuracy better than +- 10% could be obtained with a single 1 cm/sup 2/ detector at fluence levels greater than 3.5 x 10/sup 4/ n/cm/sup 2/, and +- 20% at fluence levels greater than 8.6 x 10/sup 3/ n/cm/sup 2/. The volume occupied by a single 1 cm/sup 2/ area surface-barrier detector could be as small as 0.1 cm/sup 3/, satisfying the requirement of miniaturization for many JTA applications.