Radiant energy – Invisible radiant energy responsive electric signalling – Infrared responsive
Patent
1994-09-26
1996-07-30
Hannaher, Constantine
Radiant energy
Invisible radiant energy responsive electric signalling
Infrared responsive
250301, 2503418, 2504611, 356445, 356446, G01N 2117, G01N 2135, G01N 2164
Patent
active
055414133
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND
1. The Field of the Invention
The present invention is related to a system and process for inspecting surfaces. More particularly, the present invention is related to a system for obtaining near real time, nondestructive detection and evaluation of various materials on surfaces by directing light at the surface and analyzing the intensity and polarity of the light emanating from the surface at a wavelength corresponding to a known optical property of a predetermined material.
2. Technical Background
A typical manufacturing process utilized in many applications is the bonding of two materials. The criticality of the strength of the bond will vary depending on the particular application for which the bonded material is to be used. For example, in the manufacture of solid rocket motors, bond strength is particularly critical.
The bonds in a solid rocket motor can be subjected to forces of high magnitude due to acceleration, ignition pressurization and thermal loads. A weak bond or area of debonding can be the source of stress risers which can result in further weakening of the bond, eventually leading to failure of the bond, and can distort the geometry of the bonded material thereby adversely affecting the firing characteristics of the motor.
In the manufacture of a solid rocket motor, a variety of materials must be successfully bonded to one another. For example, some of the bonds found in a typical solid rocket motor are the bond between the case and the insulator, between the insulator and the liner, between the liner and the propellant and between the nozzle phenolic and the metal nozzle housing. A weak bond or debond in any of these bonds could result in catastrophic failure of the rocket motor.
When two materials are bonded together, contaminants on the surface of either of the materials can weaken the bond and, in some instances, cause areas of debonding. Organic materials such as greases, hydraulic fluids and mold release agents are the primary source of contamination of bonding surfaces in solid rocket motors. Other contaminants include particulates such as sand or dust. Oil vapors are often present in environments where hydraulic systems and electric motors are present. These vapors can condense on surfaces to be bonded. Even small levels of these contaminants, not visible to the human eye, can degrade bond strength.
The extent to which a surface can be cleaned prior to bonding and the method to be utilized in cleaning the surface vary according to the nature of the surface. For example, the rocket case of the space shuttle is a grit-blasted steel surface. It is typically cleaned by a vapor degrease process. According to one such process, the case is suspended within a pit in the bottom of which boiling methylchloroform is located. The methylchloroform evaporates and condenses on the rocket case. As it runs off the rocket case, it dissolves any grease in its path. While this process works well in cleaning small amounts of grease from the rocket case, if there are areas of localized buildup of grease, not all of the grease may be removed by the cleaning process.
Using a solvent such as methylchloroform to clean a bonding surface may not be viable if the bonding surface is a phenolic material. In a solid rocket motor the nozzle is typically made of a phenolic material. The nozzle is made by wrapping uncured tape onto a mandrel, permitting the tape to cure and then machining the part into the desired shape.
Phenolic materials will absorb virtually any type of cleaning solvent with which they come into contact. These solvents can alter the surface chemistry and/or carry dissolved contaminants into the phenolic. In applications such as those discussed herein, the surface properties of the phenolics must remain unchanged.
Presently, the preferred method of cleaning a phenolic material is to place it on the mill and machine a new surface, thereby removing the contaminated surface. However, this can only be done if the tolerances of the part permit a portion of the surface to be removed. Otherw
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Nicolet IR Micros
Doyle Timothy E.
Johnson Kendall B.
Pearson Lee H.
Hannaher Constantine
Lyons Ronald L.
Thiokol Corporation
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