Eddy Currents

Aerospace has a reputation for applying novel techniques developed in the laboratory to difficult problems encountered in the field. For example, when a cracked flight nozzle on a Delta rocket's graphite epoxy motor was dissected, analysts discovered that the ply angles in its liner were significantly out of tolerance. Suddenly, the flightworthiness of more than 200 stored nozzles was called into question. The immediate concern focused on the 18 nozzles on the Delta GPS IIR-10 and IIR-11 vehicles being readied for launch. Aerospace made significant contributions to an eddy-current method for ply-angle measurement that was subsequently developed by the contractor. Eddy-current inspection is based on generating or inducing electrical eddy currents in a workpiece and understanding how they respond to the presence of flaws or material changes such as subsurface cracks, voids, impurities, and corrosion. The technique was used to survey the nozzles for the current inventory of more than 100 production motors. Aerospace then went on to develop and apply an alternate ultrasonic technique with even greater accuracy. These methods played a crucial role in the launch-readiness verification for these two missions as well as the GPS IIR-12 thru IIR-15 and MiTEx missions.


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