July 2013 

NASA/TM2013-218021/Volume II 

NESC-RP-12-00824 

 

Independent Assessment of Instrumentation for 

ISS On-Orbit NDE 

Appendices 

Eric I Madaras/NESC 

Langley Research Center, Hampton, Virginia 
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July 2013 

NASA/TM2013-218021/Volume II 

NESC-RP-12-00824 

 

Independent Assessment of Instrumentation for 

ISS On-Orbit NDE 

Appendices 

Eric I Madaras/NESC 

Langley Research Center, Hampton, Virginia 
Available from: 

NASA Center for AeroSpace Information 

7115 Standard Drive 

Hanover, MD 21076-1320 

443-757-5802 

Acknowledgments 

Significant Contributors to this report were: 

William Prosser LaRC 

Ajay Koshti JSC 

Miles Skow KSC 

Dave Stanley JSC/Jacobs Technology 

Bruce Blazine JSC/United Space Alliance 

Dan Perri JSC/Jacobs Technology 

Chris Sinclair JSC/Jacobs Technology 

Bert Young JSC/United Space Alliance 

Todd Hong JSC 

Kornel Nagy JSC 

George Studor JSC 

The use of trademarks or names of manufacturers in the report is for accurate reporting and does not 

constitute an official endorsement, either expressed or implied, of such products or manufacturers by the 

National Aeronautics and Space Administration. 
NASA Engineering and Safety Center 

Technical Assessment Report

Document #: 

NESC-RP12-00824

Version: 

1.0

Title:

Independent Assessment of Instrumentation 

for ISS On-orbit NDE 

Page #: 

1 of 396

NESC Request No.: TI-12-00824 

Volume II 

Appendices 

Independent Assessment of Instrumentation 

for International Space Station (ISS) On-orbit 

Nondestructive Evaluation (NDE) 

May 16, 2013
NASA Engineering and Safety Center 

Technical Assessment Report

Document #: 

NESC-RP09-00565

Version: 

1.0

Title:

Independent Assessment of Instrumentation 

for ISS On-orbit NDE 

Page #: 

2 of 396

NESC Request No.: TI-12-00824 

Volume II. Appendices 

Appendix A. “MPLM Post-Proof Test Inspection Status,” Presented to the SSPCB, 

February 14, 2005 ............................................................................................................... 3

Appendix B. Presentation to SRB: MMOD Excerpts .............................................................................. 8

Appendix C. Manufactured Test Articles............................................................................................... 10

Appendix D. Olympus Omniscan MX UT Results ................................................................................ 20

Appendix E. Sonatest Veo Results ........................................................................................................ 95

Appendix F. General Electric® PhasorTM Results ................................................................................ 160

Appendix G. Olympus Omniscan MX EC Results .............................................................................. 209

Appendix H. UniWest® 454A/ECS3 Results ....................................................................................... 256

Appendix I. Jentek® GridStation® Results .......................................................................................... 303

Appendix J. Astronaut Assessment Report ......................................................................................... 350

Appendix K. Operations Assessment Report ....................................................................................... 361

Appendix L. Engineering Assessment Report ..................................................................................... 365
NASA Engineering and Safety Center 

Technical Assessment Report

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Version: 

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Independent Assessment of Instrumentation 

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NESC Request No.: TI-12-00824 

Appendix A. “MPLM Post-Proof Test Inspection Status,” 

Presented to the Space Station Program Control Board 

(SSPCB), February 14, 2005

MPLM Post-Proof Test Inspection 

Status

Last Updated 2/14/05

Chris Hansen

Kornel Nagy

Al Parrish

NASA-JSC Engineering

Page No. 2

Completed Work

• Single-sided Eddy-Current inspections completed for FM2

– No flaws identified

• Peaking and mismatch data verified and updated

• MPLM Finite Element Models verified

– NASA and Boeing experts worked with Alenia to evaluate existing 

MPLM models

– Stress states for MPLM now well understood

– Peaking and mismatch effects on weld stress well understood 

(peaking shown to have a large effect on stress levels)

• MPLM Load spectrum development completed

• Fracture analysis for FM-2 is now complete
NASA Engineering and Safety Center 

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NESC Request No.: TI-12-00824 

Page No. 3

Analysis Results Summary

• The minimum Critical Initial Flaw Size (CIFS) for the MPLM, 

using recent as-measured data was calculated to be 74mm 

(~3 in.)

– Full table of results is included in back-up charts

• With an assumed flaw that is 90% through the thickness of 

the weld (the largest assumed flaw that we could have 

missed during inspections), the MPLM shows a capability of 

surviving a 5 mission profile

– 1 mission profile consists of 25 flights

– This data is valid for both as-built measurements for 

peaking/mismatch, and spec values (up to 5° peaking)

Page No. 4

Conclusions for FM-2

• Based on available data, he position of the JSC Fracture 

Control Board and JSC Engineering is that FM2 is currently 

certified for 1 more flight with no waiver rationale required

– The FCB would like to see the results of the Simulated Service 

testing before clearing FM2 for life, but positive results based on 

experience and already completed testing lead to a high level of 

confidence that FM2 will be cleared for life with no further testing, or 

waiver, required 

• MSFC Fracture Control Board has not completed their 

assessment for flight certification
NASA Engineering and Safety Center 

Technical Assessment Report

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Independent Assessment of Instrumentation 

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NESC Request No.: TI-12-00824 

Page No. 5

Future Work – FM1

• Actual peaking and mismatch measurements for FM1 is 

complete, therefore stress models and load spectrums from 

FM2 can be used since they envelope FM1

Page No. 6

Future Work – FM1

• Option 1: perform a single-sided eddy current inspection of 

FM1, equivalent to inspections performed on FM2

– Will certify FM1 for 1 flight, and probably for life based on final 

results from Simulated Service testing

– No waiver required

– Recommended option by JSC Eng. and JSC FCB

• Option 2: Perform a single-sided eddy current inspection of 

FM1 radial welds only

– Will certify FM1 for 1 flight only, with a waiver required, but JSC 

Eng. and JSC FCB find this a technically acceptable option

– Inspection of all welds missed during initial inspection will have to be 

completed before following FM1 flight

• Option 3: No inspection

– Not supported by JSC Eng or JSC FCB

– Effect of peaking on weld stresses very severe and not accounted 

for in original analysis, does not meet fracture control reqts. 

• Recommendations do not include MSFC FCB or NESC yet
NASA Engineering and Safety Center 

Technical Assessment Report

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NESC Request No.: TI-12-00824 

Page No. 7

Back-up charts

Page No. 8

Analysis Results

Critical Initial Flaw Size

(CIFS) (mm)

Max Tension 76

Max Bending 136

Max Tension 74

Max Bending 136

Max Tension 66

Max Bending 136

2

0.5

0.5

Stress Combination

0.0

No. Peaking Angle

(deg)

Mismatch

(mm)

3

2.5 (2)

3.15 (3)

5.0 (4)

1

Life

Start Failed

1 2.5 (2) 0.5 Max Tension Yes Yes 6.3 / 63 79 6

Yes Yes 6.3 / 63 NA <1 (5)

No Yes 6.3 / 63 76 5

Max Bending Yes Yes 6.3 / 63 6.417 / 65.2 50 +

No Yes 6.3 / 63 77 5 No No 6.3 / 63 69 7

Max Bending Yes Yes 6.3 / 63 6.35 / 65.7 50+

Max Tension

Max Tension

No. Peaking Angle

(deg)

Mismatch

(mm) Proof Cycles Ground Press

 Cycle

Flaw Size (depth/length) mm

3

Stress

Combination

2 3.15 (3)

5.0 (4)

0.5

0.0

(5) 1 life = 25 MPLM flights for this analysis

Spec peaking value

As measured peaking data

As-built Alenia data
NASA Engineering and Safety Center 

Technical Assessment Report

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NESC Request No.: TI-12-00824 

Page No. 9

Weld Locations

C

1

C

2

R

1

R

2

R

3

R

4

R

5

R

6 R1

0

R

7

R

8

R

9

C

3

C

4

C

5

C

6

C

7

C

8 L

1

L

2

L

3

L

4

L

5

L

6

L

7

L

8

L

9

L1

0

+

Z

+

Y

+

XAF

T

AFT 

Cone

AFT 

Cylinder

FWD

Cylinder

FWD

Cone

C = Circumferential Weld

L = Longitudinal Weld

R = Radial Weld
NASA Engineering and Safety Center 

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Independent Assessment of Instrumentation 

for ISS On-orbit NDE 

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NESC Request No.: TI-12-00824 

Appendix B. Presentation to SRB: MMOD Excerpts

5/8/2013 1

Systems Engineering and Integration 

Office

Presentation to SRB 

4/26/2013

MMOD Excerpts

Page No. 11

Pre-decisional, For Internal Use Only

MMOD Risk

10 Year Risk Assessment

ISS MMOD Risks

10-year future time period, updated with latest NASA results documented in JSC-65837 and JSC-66198

Date Penetration Risk Loss-of-crew (LOC) 

Risk

Evacuation Risk due to 

MMOD

Requirement (Penetration Risk)

Goal (LOC Risk)

 24% 

(PNP=0.76)  5% (PNCF=0.95) NA

Assessed ISS Risk

In March 2012 March 2012 52% (PNP=0.48) 8.0% (PNCF=0.920) 16.1% (PNevac=0.839)

With partial implementation of 

Progress enhancement beginning 

with 47P

April 2012 49.0% 

(PNP=0.510) 7.6% (PNCF=0.924) 14.4% (PNevac=0.856)

Above and Soyuz enhancement 

beginning with 30S May 2012 34.5% (PNP=0.655) 5.2% (PNCF=0.948) 14.3% (PNevac=0.857)

Above and 5 SM debris panels 

installed on RS EVA 31 August 2012 33.9% 

(PNP=0.661) 5.1% (PNCF=0.949) 13.7% (PNevac=0.863)

Above and full implementation of 

Progress enhancement beginning 

with 57P

October 2014 28.0% 

(PNP=0.720) 4.6% (PNCF=0.954) 11.0% (PNevac=0.890)

Above and commercial crew 

vehicles beginning in 2017 (reduce 

Soyuz flights)

2017 26.5% 

(PNP=0.735)** 4.4% (PNCF=0.956) 11.0% (PNevac=0.890)

** The future mix of visiting vehicles subject to change. As commercial crew and cargo vehicles replace Soyuz/Progress vehicles, ISS MMOD risks will improve.

Completed Planned
NASA Engineering and Safety Center 

Technical Assessment Report

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Independent Assessment of Instrumentation 

for ISS On-orbit NDE 

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NESC Request No.: TI-12-00824 

Page No. 12

Pre-decisional, For Internal Use Only

MMOD Risk

10 Year Risk Assessment • MMOD risk assessments will be updated after the new orbital debris model 

(ORDEM 3.0) is released, and as additional elements are added to ISS.

– Overall ISS MMOD Risks will likely increase with these changes, although risks for 

some modules will decrease while others (mainly Russian visiting vehicles) will 

increase

• “Penetration” is a hole in pressure shell of crew modules, damage/hole in 

external pressure vessels, damage to CMG rotors (i.e., MMOD damage that 

endangers crew &/or ISS survivability)

– 90% of the MMOD penetration risk is due to RS elements, 10% of risk due to 

NASA/ESA/JAXA elements

• Loss-of-crew (LOC) risk results from rapid depress due to MMOD 

penetration, internal fragments causing LOC injury, and other catastrophic 

failure modes.

• Evacuation from MMOD results if some or all crew are evacuated due to 

non-fatal injury to crew (requiring evac), rapid depress (uncontrolled 

depress) or loss of critical functions (SM or Node 3 depress). No loss of crew 

risk is included in the evac risk assessment.

Page No. 13

Pre-decisional, For Internal Use Only

MMOD Risk

Penetration Risk Over Time
NASA Engineering and Safety Center 

Technical Assessment Report

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NESC Request No.: TI-12-00824 

Appendix C. Manufactured Test Articles

NDE Flaw Detectability 

Feasibility Study Standards

September 12, 2012

Ajay Koshti 1

Summary of NDE Standards

Standard # Description Qty

Plate 

Thickness Construction Usage Notes

Fabricated 

By

1A Iso-grid plate with notches and flat bottom holes, flaws on grid 

side 

1 0.436" Iso-grid flat Simulates FGB pressure wall MMOD 

damage

LaRC

1B Iso-grid plate with notches and flat bottom holes, flaws on flat 

side 

1 0.436" Iso-grid flat Simulates FGB pressure wall MMOD 

damage

LaRC

2 Flat plate with notches and flat bottom holes along two lines 2 0.1875 Flat Simulates US module MMOD damage, 

shear wave from a distance with and 

without patch

LaRC

3 Flat plate with flat bottom holes in circular pattern 1 0.1875 Flat Simulates US module MMOD damage, 

shear wave from a distance with and 

without patch

JSC

4 Flat plate with notches and flat bottom holes along two lines 2 0.0625 Flat Simulates FGB pressure wall MMOD

damage with and without patch

LaRC

5 Flat plate with flat bottom holes in circular pattern 1 0.0625 Flat Simulates FGB pressure wall MMOD 

damage with and without patch

JSC

6A Curved plate with notches and flat bottom holes along two lines, 

notches parallel to curved edge

1 0.1875 83" radius Simulates US module MMOD damage, 

shear wave from a distance with and 

without patch

JSC

6B Curved plate with notches and flat bottom holes along two lines, 

notches parallel to straight edge

1 0.1875 83" radius Simulates US module MMOD damage, 

shear wave from a distance with and 

without patch

JSC

7A Curved plate with notches and flat bottom holes along two lines, 

notches parallel to curved edge

1 0.1875 25" radius Simulates US module MMOD damage, 

shear wave from a distance with and 

without patch

JSC

7B Curved plate with notches and flat bottom holes along two lines, 

notches parallel to straight edge

1 0.1875 25" radius Simulates US module MMOD damage, 

shear wave from a distance with and 

without patch

JSC

Note: Autocad files or pdf copies of individual drawings are available 

2
NASA Engineering and Safety Center 

Technical Assessment Report

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NESC Request No.: TI-12-00824 

NDE Standard 1A and 1B: Graphics

Quantity

1A: 1 ea

1B: 1 ea

Simulates Russian module pressure wall

3

NDE Standard 1: Notes Part 

Name: NDE Standard 1A

Part Description: Flat plate with drilled holes and EDM slots

Annotati

on Annotated Entity Description Other Description

S1 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along fillet radius, 45 deg

S2 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along fillet radius, 0 deg

S3 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along fillet radius, -45 deg

S4 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along the tangent of the fillet radius, 135 deg

S5 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along the tangent of the fillet radius, 90 deg

S6 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along the tangent of the fillet radius, 45 deg

S7 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along 90 deg

S8 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along 90 deg

S9 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along fillet radius, 45 deg

S10 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along fillet radius, 0 deg

S11 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along fillet radius, -45 deg

S12 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along the tangent of the fillet radius, 135 deg

S13 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along the tangent of the fillet radius, 90 deg

S14 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along the tangent of the fillet radius, 45 deg

S15 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along 90 deg

S16 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along 90 deg

H1 Drilled Hole Diameter 3/64, Depth 0.010 +/-0.003

H2 Drilled Hole Diameter 3/64, Depth 0.010 +/-0.003

H3 Drilled Hole Diameter 3/64, Depth 0.010 +/-0.003

H4 Drilled Hole Diameter 3/64, Depth 0.010 +/-0.003

H5 Drilled Hole Diameter 3/64, Depth 0.010 +/-0.003

H6 Drilled Hole Diameter 3/64, Depth 0.010 +/-0.003

H7 Drilled Hole Diameter 3/64, Depth 0.020 +/-0.003

H8 Drilled Hole Diameter 3/64, Depth 0.020 +/-0.003

H9 Drilled Hole Diameter 3/64, Depth 0.020 +/-0.003

H10 Drilled Hole Diameter 3/64, Depth 0.020 +/-0.003

H11 Drilled Hole Diameter 3/64, Depth 0.020 +/-0.003

H12 Drilled Hole Diameter 3/64, Depth 0.020 +/-0.003

General Notes

1Material: AL 6061 T6

2Dimensions in inches.

3Locate slots and holes as indicated using a full scale template on flat side

4Tolerance: X.X = +/-0.1, X.XX = +/- 0.01, X.XXX = 0.002 Unless Otherwise Specified.

5Surface finish 63 RHR or better. Break sharp edges and corners.

6Use flat tip drill for drilled holes

7Drilled holes and slots are machined normal to the local surface on the Flat side

Ajay Koshti, August 14, 2012

4
NASA Engineering and Safety Center 

Technical Assessment Report

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NESC Request No.: TI-12-00824 

NDE Standard 1B: Notes Part 

Name: NDE Standard 1B

Part Description: Flat plate with drilled holes and EDM slots

Annotatio

n Annotated Entity Description Other Description

S1 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along fillet radius, 45 deg

S2 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along fillet radius, 0 deg

S3 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along fillet radius, -45 deg

S4 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along the tangent of the fillet radius, 135 deg

S5 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along the tangent of the fillet radius, 90 deg

S6 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along the tangent of the fillet radius, 45 deg

S7 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along 90 deg

S8 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003 Length along 90 deg

S9 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along fillet radius, 45 deg

S10 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along fillet radius, 0 deg

S11 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along fillet radius, -45 deg

S12 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along the tangent of the fillet radius, 135 deg

S13 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along the tangent of the fillet radius, 90 deg

S14 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along the tangent of the fillet radius, 45 deg

S15 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along 90 deg

S16 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003 Length along 90 deg

H1 Drilled Hole Diameter 3/64, Depth 0.010 +/-0.003

H2 Drilled Hole Diameter 3/64, Depth 0.010 +/-0.003

H3 Drilled Hole Diameter 3/64, Depth 0.010 +/-0.003

H4 Drilled Hole Diameter 3/64, Depth 0.010 +/-0.003

H5 Drilled Hole Diameter 3/64, Depth 0.010 +/-0.003

H6 Drilled Hole Diameter 3/64, Depth 0.010 +/-0.003

H7 Drilled Hole Diameter 3/64, Depth 0.020 +/-0.003

H8 Drilled Hole Diameter 3/64, Depth 0.020 +/-0.003

H9 Drilled Hole Diameter 3/64, Depth 0.020 +/-0.003

H10 Drilled Hole Diameter 3/64, Depth 0.020 +/-0.003

H11 Drilled Hole Diameter 3/64, Depth 0.020 +/-0.003

H12 Drilled Hole Diameter 3/64, Depth 0.020 +/-0.003

General Notes

1Material: AL 6061 T6

2Dimensions in inches.

3Locate slots and holes visiblly centered as indicated 

4Tolerance: X.X = +/-0.1, X.XX = +/- 0.01, X.XXX = 0.002 Unless Otherwise Specified.

5Surface finish 63 RHR or better. Break sharp edges and corners.

6Use flat tip drill for drilled holes

7Drilled holes and slots are machined normal to the local surface on the iso-grid side

5

NDE Standard 2

Quantity: 2 ea

Simulates US module pressure 

wall

For NDE flaw detectability study 

with or without patch or dome 

repair

6
NASA Engineering and Safety Center 

Technical Assessment Report

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NESC Request No.: TI-12-00824 

NDE Standard 2: Notes Part Name: NDE Standard 2

Part Description: Flat plate with drilled holes and EDM slots

Hex Notes Annotated Entity Description

0Plate AL 6061 T6, 0.1875 +/-0.002 Thick, 12.00 Long X 12.00 Wide

1Drilled Hole Diameter 1/32, Depth 0.025 +/-0.003

2Drilled Hole Diameter 1/32, Depth 0.050 +/-0.003

3Drilled Hole Diameter 1/32, Depth 0.075 +/-0.003

4Drilled Hole Diameter 1/16, Depth 0.025 +/-0.003

5Drilled Hole Diameter 1/16, Depth 0.050 +/-0.003

6Drilled Hole Diameter 1/16, Depth 0.075 +/-0.003

7Drilled Hole Diameter 3/32, Depth 0.025 +/-0.003

8Drilled Hole Diameter 3/32, Depth 0.050 +/-0.003

9Drilled Hole Diameter 3/32, Depth 0.075 +/-0.003

10Drilled Hole Diameter 3/32, Depth 0.100 +/-0.003

11EDM Slot Length 0.032 +/-0.005, Width 0.003 -0.006, Depth 0.025 +/-0.003

12EDM Slot Length 0.032 +/-0.005, Width 0.003 -0.006, Depth 0.050 +/-0.003

13EDM Slot Length 0.032 +/-0.005, Width 0.003 -0.006, Depth 0.075 +/-0.003

14EDM Slot Length 0.063 +/-0.005, Width 0.003 -0.006, Depth 0.100 +/-0.003

15EDM Slot Length 0.063 +/-0.005, Width 0.003 -0.006, Depth 0.125 +/-0.003

16EDM Slot Length 0.063 +/-0.005, Width 0.003 -0.006, Depth 0.025 +/-0.003

17EDM Slot Length 0.094 +/-0.005, Width 0.003 -0.006, Depth 0.050 +/-0.003

18EDM Slot Length 0.094 +/-0.005, Width 0.003 -0.006, Depth 0.075 +/-0.003

19EDM Slot Length 0.094 +/-0.005, Width 0.003 -0.006, Depth 0.100 +/-0.003

20EDM Slot Length 0.094 +/-0.005, Width 0.003 -0.006, Depth 0.125 +/-0.003

General Notes

1Dimensions in inches.

2Location Tolerances for Holes and Slots: +/- 0.010.

3Tolerance: X.X = +/-0.1, X.XX = +/- 0.01, X.XXX = 0.002 Unless Otherwise Specified.

4Surface finish 63 RHR or better. Break sharp edges and corners.

5Use 120 degree tipped drill for drilled holes.

7

NDE Standard 3

Simulates US module 

pressure wall.

For NDE flaw detectability 

study under patch or dome 

repair

Quantity: 1 ea

8
NASA Engineering and Safety Center 

Technical Assessment Report

Document #: 

NESC-RP09-00565

Version: 

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Title:

Independent Assessment of Instrumentation 

for ISS On-orbit NDE 

Page #: 

14 of 396

NESC Request No.: TI-12-00824 

NDE Standard 3: Notes Part Name NDE Standard 3

Part Description Flat Plate with Drilled Holes

Numbered Hex Notes Diameter Depth Numbered Hex Notes Diameter Depth

1 0.031 0.025 25 0.063 0.125

2 0.031 0.050 26 0.063 0.100

3 0.031 0.075 27 0.063 0.075

4 0.031 0.100 28 0.063 0.050

5 0.031 0.125 29 0.063 0.025

6 0.031 0.025 30 0.063 0.125

7 0.031 0.050 31 0.063 0.100

8 0.031 0.075 32 0.063 0.075

9 0.031 0.100 33 0.063 0.050

10 0.031 0.125 34 0.063 0.025

11 0.031 0.025 35 0.063 0.050

12 0.031 0.050 36 0.063 0.025

13 0.031 0.075 37 0.094 0.125

14 0.031 0.100 38 0.094 0.100

15 0.031 0.125 39 0.094 0.075

16 0.031 0.025 40 0.094 0.050

17 0.031 0.050 41 0.094 0.025

18 0.031 0.075 42 0.094 0.125

19 0.031 0.100 43 0.094 0.100

20 0.031 0.125 44 0.094 0.075

21 0.031 0.050 45 0.094 0.050

22 0.031 0.075 46 0.094 0.025

23 0.031 0.100 47 0.094 0.125

24 0.031 0.125 48 0.094 0.100

Letter Hex Note

A Hole Diameter 1.000+/- 0.005, Depth 0.100 +/- 0.005, Inner Fillet Radius 0.032 +/- 0.005

General Notes

1 AL 6061 T6, 0.1875 +/-0.002 Thick, 12.00 Long X 12.00 Wide

2 Dimensions in Inches.

3 Hex note number is same as hole #. Drilled holes are arranged on three circles. Hole numbers are counted clockwise on each circle.

4 Hole # 1 through 48 are drilled with 120 deg. tip angle drills

5 Drilled Hole Tolerance: Diameter +/- 0.005, Depth +/- 0.002

6 Location Tolerance for Holes : +/- 0.010 and +/-2 Deg

7 Dimensional Tolerance: X.X = +/-0.1, X.XX = +/- 0.01, X.XXX = 0.002 Unless Otherwise Specified.

8 Surface finish 63 RHR or better. Deburr holes. Break external sharp edges and corners.

9 Use 120 degree tipped drill for drilled holes. 9

NDE Standard 4

Simulates Russian module 

pressure wall

For NDE flaw detectability study 

with or without patch or dome 

repair

Quantity: 2 ea

10
NASA Engineering and Safety Center 

Technical Assessment Report

Document #: 

NESC-RP09-00565

Version: 

1.0

Title:

Independent Assessment of Instrumentation 

for ISS On-orbit NDE 

Page #: 

15 of 396

NESC Request No.: TI-12-00824 

Part Name NDE Standard 4

Part Description: Flat plate with drilled holes and EDM slots

Hex Notes Annotated Entity Description

0 Plate AL 6061 T6, 0.063 +/-0.002 Thick, 12.00 Long X 12.00 Wide

1 Drilled Hole Diameter 1/32, Depth 0.010 +/-0.003

2 Drilled Hole Diameter 1/32, Depth 0.020 +/-0.003

3 Drilled Hole Diameter 1/32, Depth 0.030 +/-0.003

4 Drilled Hole Diameter 1/16, Depth 0.010 +/-0.003

5 Drilled Hole Diameter 1/16, Depth 0.020+/-0.003

6 Drilled Hole Diameter 1/16, Depth 0.030 +/-0.003

7 Drilled Hole Diameter 3/32, Depth 0.010 +/-0.003

8 Drilled Hole Diameter 3/32, Depth 0.020 +/-0.003

9 Drilled Hole Diameter 3/32, Depth 0.030 +/-0.003

10 Drilled Hole Diameter 3/32, Depth 0.040 +/-0.003

11 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.005 +/-0.002

12 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003

13 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003

14 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.030 +/-0.003

15 EDM Slot Length 0.100 +/-0.005, Width 0.003 -0.006, Depth 0.040 +/-0.003

16 EDM Slot Length 0.200 +/-0.005, Width 0.003 -0.006, Depth 0.005 +/-0.003

17 EDM Slot Length 0.200 +/-0.005, Width 0.003 -0.006, Depth 0.010 +/-0.003

18 EDM Slot Length 0.200 +/-0.005, Width 0.003 -0.006, Depth 0.020 +/-0.003

19 EDM Slot Length 0.200 +/-0.005, Width 0.003 -0.006, Depth 0.030 +/-0.003

20 EDM Slot Length 0.200 +/-0.005, Width 0.003 -0.006, Depth 0.040 +/-0.003

General Notes

1 Dimensions in inches.

2 Location Tolerances for Holes and Slots: +/- 0.010.

3 Tolerance: X.X = +/-0.1, X.XX = +/- 0.01, X.XXX = 0.002 Unless Otherwise Specified.

4 Surface finish 63 RHR or better. Break sharp edges and corners.

5 Surface finish 63 RHR or better. Break sharp edges and corners.

6 Use flat tip drill for drilled holes

Ajay Koshti, July 9, 2012

NDE Standard 4

11

NDE Standard 5

12

Simulates Russian module pressure 

wall

Quantity: 1 ea

12
NASA Engineering and Safety Center 

Technical Assessment Report

Document #: 

NESC-RP09-00565

Version: 

1.0

Title:

Independent Assessment of Instrumentation 

for ISS On-orbit NDE 

Page #: 

16 of 396

NESC Request No.: TI-12-00824 

Part Name NDE Standard 5

Part Description Flat plate with drilled holes

Numbered Hex Notes Diameter Depth Numbered Hex Notes Diameter Depth

1 0.031 0.005 25 0.063 0.005

2 0.031 0.010 26 0.063 0.010

3 0.031 0.015 27 0.063 0.015

4 0.031 0.020 28 0.063 0.020

5 0.031 0.025 29 0.063 0.025

6 0.031 0.030 30 0.063 0.030

7 0.031 0.035 31 0.063 0.035

8 0.031 0.040 32 0.063 0.040

9 0.031 0.005 33 0.063 0.025

10 0.031 0.010 34 0.063 0.030

11 0.031 0.015 35 0.063 0.035

12 0.031 0.020 36 0.063 0.040

13 0.031 0.025 37 0.094 0.005

14 0.031 0.030 38 0.094 0.010

15 0.031 0.035 39 0.094 0.015

16 0.031 0.040 40 0.094 0.020

17 0.031 0.005 41 0.094 0.025

18 0.031 0.010 42 0.094 0.030

19 0.031 0.015 43 0.094 0.035

20 0.031 0.020 44 0.094 0.040

21 0.031 0.025 45 0.094 0.025

22 0.031 0.030 46 0.094 0.030

23 0.031 0.035 47 0.094 0.035

24 0.031 0.040 48 0.094 0.040

Letter Hex Note

A Hole Diameter 1.000+/- 0.005, Through Hole

General Notes

1 AL 6061 T6, 0.063 +/-0.002 Thick, 12.00 Long X 12.00 Wide

2 Dimensions in inches.

3 Hex note number is same as hole #. Drilled holes are arranged on three circles. Hole numbers are counted clockwise 

on each circle

4 Hole # 1 through 48 are drilled with flat tip drills

5 Drilled Hole Tolerance: Diameter +/- 0.005, Depth +/- 0.002

6 Location tolerance for holes : +/- 0.010 and +/-2 Deg

7 Dimensional tolerance: X.X = +/-0.1, X.XX = +/- 0.01, X.XXX = 0.002 Unless Otherwise Specified.

8 Surface finish 63 RHR or better. Deburr holes. Break external sharp edges and corners.

NDE Standard 5

13

NDE Standard 6A

Quantity: 

6A: 1 ea

83” Radius 

14
NASA Engineering and Safety Center 

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Version: 

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Title:

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for ISS On-orbit NDE 

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NDE Standard 6B

Simulates Russian 

module pressure wall

Quantity: 1 ea

15

NDE Standard 6A and 6B

Part Name: NDE Standard 6A and 6B

Part Description: Curved plate with drilled holes and EDM slots

Hex Notes Annotated Entity Description

0 Plate AL 6061 T6, 0.1875 +/-0.002 Thick, 12.00 Long X 12.00 Wide

1 Drilled Hole Diameter 1/32, Depth 0.025 +/-0.003

2 Drilled Hole Diameter 1/32, Depth 0.050 +/-0.003

3 Drilled Hole Diameter 1/32, Depth 0.075 +/-0.003

4 Drilled Hole Diameter 1/16, Depth 0.025 +/-0.003

5 Drilled Hole Diameter 1/16, Depth 0.050 +/-0.003

6 Drilled Hole Diameter 1/16, Depth 0.075 +/-0.003

7 Drilled Hole Diameter 3/32, Depth 0.025 +/-0.003

8 Drilled Hole Diameter 3/32, Depth 0.050 +/-0.003

9 Drilled Hole Diameter 3/32, Depth 0.075 +/-0.003

10 Drilled Hole Diameter 3/32, Depth 0.100 +/-0.003

11 EDM Slot Length 0.032 +/-0.005, Width 0.003 -0.006, Depth 0.025 +/-0.003

12 EDM Slot Length 0.032 +/-0.005, Width 0.003 -0.006, Depth 0.050 +/-0.003

13 EDM Slot Length 0.032 +/-0.005, Width 0.003 -0.006, Depth 0.075 +/-0.003

14 EDM Slot Length 0.063 +/-0.005, Width 0.003 -0.006, Depth 0.100 +/-0.003

15 EDM Slot Length 0.063 +/-0.005, Width 0.003 -0.006, Depth 0.125 +/-0.003

16 EDM Slot Length 0.063 +/-0.005, Width 0.003 -0.006, Depth 0.025 +/-0.003

17 EDM Slot Length 0.094 +/-0.005, Width 0.003 -0.006, Depth 0.050 +/-0.003

18 EDM Slot Length 0.094 +/-0.005, Width 0.003 -0.006, Depth 0.075 +/-0.003

19 EDM Slot Length 0.094 +/-0.005, Width 0.003 -0.006, Depth 0.100 +/-0.003

20 EDM Slot Length 0.094 +/-0.005, Width 0.003 -0.006, Depth 0.125 +/-0.003

General Notes

1 Dimensions in inches.

2 Location Tolerances for Holes and Slots: +/- 0.010.

3 Tolerance: X.X = +/-0.1, X.XX = +/- 0.01, X.XXX = 0.002 Unless Otherwise Specified.

4 Surface finish 63 RHR or better. Break sharp edges and corners.

5 For standard 6A, notch lengths are parallel to curved edge of the part

6 For standard 6B, notch lengths are parallel to straight edge of the part

7 Curved plate inner radius: 83 +/- 5

8 Holes and notches are machined perpendicular to machined surface from the convex side 

9 Use 120 degree tipped drill for drilled holes.

16

 
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NDE Standard 7A

Simulates Russian 

module pressure wall

Quantity: 1 ea

17

NDE Standard 7B

Simulates Russian 

module pressure wall

Quantity: 1 ea

18
NASA Engineering and Safety Center 

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Version: 

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for ISS On-orbit NDE 

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Part Name: NDE Standard 7A and 7B

Part Description: Curved plate with drilled holes and EDM slots

Hex Notes Annotated Entity Description

0 Plate AL 6061 T6, 0.1875 +/-0.002 Thick, 12.00 Long X 12.00 Wide

1 Drilled Hole Diameter 1/32, Depth 0.025 +/-0.003

2 Drilled Hole Diameter 1/32, Depth 0.050 +/-0.003

3 Drilled Hole Diameter 1/32, Depth 0.075 +/-0.003

4 Drilled Hole Diameter 1/16, Depth 0.025 +/-0.003

5 Drilled Hole Diameter 1/16, Depth 0.050 +/-0.003

6 Drilled Hole Diameter 1/16, Depth 0.075 +/-0.003

7 Drilled Hole Diameter 3/32, Depth 0.025 +/-0.003

8 Drilled Hole Diameter 3/32, Depth 0.050 +/-0.003

9 Drilled Hole Diameter 3/32, Depth 0.075 +/-0.003

10 Drilled Hole Diameter 3/32, Depth 0.100 +/-0.003

11 EDM Slot Length 0.032 +/-0.005, Width 0.003 -0.006, Depth 0.025 +/-0.003

12 EDM Slot Length 0.032 +/-0.005, Width 0.003 -0.006, Depth 0.050 +/-0.003

13 EDM Slot Length 0.032 +/-0.005, Width 0.003 -0.006, Depth 0.075 +/-0.003

14 EDM Slot Length 0.063 +/-0.005, Width 0.003 -0.006, Depth 0.100 +/-0.003

15 EDM Slot Length 0.063 +/-0.005, Width 0.003 -0.006, Depth 0.125 +/-0.003

16 EDM Slot Length 0.063 +/-0.005, Width 0.003 -0.006, Depth 0.025 +/-0.003

17 EDM Slot Length 0.094 +/-0.005, Width 0.003 -0.006, Depth 0.050 +/-0.003

18 EDM Slot Length 0.094 +/-0.005, Width 0.003 -0.006, Depth 0.075 +/-0.003

19 EDM Slot Length 0.094 +/-0.005, Width 0.003 -0.006, Depth 0.100 +/-0.003

20 EDM Slot Length 0.094 +/-0.005, Width 0.003 -0.006, Depth 0.125 +/-0.003

General Notes

1 Dimensions in inches.

2 Location Tolerances for Holes and Slots: +/- 0.010.

3 Tolerance: X.X = +/-0.1, X.XX = +/- 0.01, X.XXX = 0.002 Unless Otherwise Specified.

4 Surface finish 63 RHR or better. Break sharp edges and corners.

5 For standard 7A, notch lengths are parallel to curved edge of the part

6 For standard 7B, notch lengths are parallel to straight edge of the part

7 Curved plate inner radius: 25 +/- 1

8 Holes and notches are machined perpendicular to machined surface from the convex side 

9 Use 120 degree tipped drill for drilled holes.

NDE Standard 7A and 7B

19
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Appendix D. Olympus Omniscan MX UT Results
NASA Engineering and Safety Center 

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Appendix G. Olympus Omniscan MX EC Results

Olympus Omniscan MX EC Results 
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Appendix H. UniWest® 454A/ECS3 Results
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Appendix I. Jentek® GridStation® Results

Jentek GridStation 
NASA Engineering and Safety Center 

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Appendix J. Astronaut Assessment Report

Nondestructive Evaluation (NDE) Commercial Off-the-shelf (COTS) 

Hardware Crew Review 

Executive Summary 

Over the life of the International Space Station (ISS) Program, there is a significant risk of 

module damage/penetration from micrometeoroid and orbital debris (MMOD) impact. Although 

there are leak repair kits on-orbit that address immediate pressure wall repair, there is currently 

no means to address long-term structural integrity after a repair (IRMA 4669). It has been 

proposed that COTS NDE equipment could be used to provide structural damage evaluation, as 

well as potential certification of the repair. In order to select the optimum COTS NDE 

instrument for on-orbit use, astronauts and engineers from NASA’s Crew Office and Mission 

Operations Directorate (MOD) Operations Support Office (OSO) performed hands-on 

evaluations of several devices using predefined criteria. 

Although each COTS NDE instrument had different graphical user interfaces (GUIs), menus, 

button layouts, and accessories, the overall astronaut feedback indicated that these instruments 

were all about the same with respect to device complexity and ease of use. In fact, all devices 

performed similarly in categories for operation, setup, teardown, crew time required, crew 

training required, and stowage volume. Ease of on-orbit operations will come down to having 

clear training videos and good procedures to operate any single instrument. However, device 

complexity and ease of use should be secondary to the device’s overall function and performance 

(as evaluated by the NDE engineering community). But, if the Crew Office were to select a 

single COTS NDE instrument to fly to the ISS in the near future, the Sonatest Veo would be the 

preferred device. This instrument was a favorite of several astronauts due to the combination of 

device capability and good display imagery. 

From a technological perspective, no show stoppers were identified, and any of the evaluated 

COTS NDE equipment could be flown to the ISS (pending typical certification requirements) 

and would provide NDE data. It is the opinion of the Crew Office that ultrasonic phased array 

(USPA) devices seemed to provide more capability over eddy current (EC) devices since USPA 

devices could scan across material where access might be blocked by the application of a 

pressure wall repair kit.

Test Description: 

The goal of the NDE project is to certify a small, portable NDE diagnostic device that can detect 

and quantify flaws or cracks within ISS structures. This information could then be used to help 

understand the risks involved in continuing to allow crew to occupy these structures. NDE 

diagnostic equipment functions similar to a doctor’s ultrasound machine and has a small LCD 

screen that highlights any defect in the scanned material. 
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As stated before, the NDE team is seeking astronaut and MOD feedback on several different 

NDE devices in order to select a single device best suited for use on the ISS. Evaluation of the 

diagnostic equipment was based on factors such as power source, NDE experience required by 

crew, ease of setup/use, access requirements, crew time, number of crew required, calibration 

requirements, and overall device performance. 

Test Dates and Location: 

November 5–8, 2012, JSC Building 9, NDE Lab (room 1004) 

Test Participants: 

x Test Directors: Dr. Eric Madaras, Dr. Ajay Koshti 

x Engineering Test Subjects: Bruce Blazine/United Space Alliance, Dan Perri/MOD, Bert 

Young/MOD, Chris Sinclair/MOD 

x Astronaut Test Subjects: Pettit, Walker, Metcalf-Linenburger, Fincke, Yui, Aunon 

x Test Report Preparation: Bruce Blazine 

COTS NDE Diagnostic Equipment: 

x Olympus MX UPAT 

x Olympus MX EC Array 

x GE Phasor UPAT 

x Sonatest Veo UPAT 

x UniWest ECS-3 

x Jentek Grid Station EC Array 

Summary Test Plan: 

1. Introductions 

2. COTS NDE description 

a. Ultrasound

b. Eddy current 

3. ISS operations scenarios 

a. Hull penetrations 

b. Light damage/suspect areas 

4. COTS NDE diagnostic equipment evaluations 

a. COTS diagnostic hardware 

b. Test samples 

Summary Test Procedure: 

1. Set up and power on of COTS NDE instrument. 

2. Load configuration file. 

3. Scan test sample. 

4. Save data file. 

5. Repeat steps 3 and 4 for each test sample. 
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6. Repeat all steps for each COTS NDE instrument. 

Astronaut Observations: 

Figure J-1. Astronaut Dr. Don Pettit Operating the Sonatest Veo System 

Table J-1. Generic NDE Crew Comments 

NDE Criteria Crew-member Observations 

NDE

Operations & 

Scanning 

Techniques 

x Using a guide/ruler helped with scanning. 

x Work with Human Research Facility (HRF) team and match their concept 

of operations, using real-time scanning feedback from ground support 

engineers. Match their training concept too (x2). 

x Will need excellent crew procedures (x3). 

x Avoid step-by-step screen shots of NDE GUI in crew procedures—it takes 

too long to read and follow. 

x Need water spray bottle/nozzle to create smaller water droplets. 

x Prefer water, avoid Braycote (too messy). 

x Using water okay, test probes with ~1-inch thick water. Probe does not 

need to be in contact with surface. 

x Equipment setup and teardown was easy (all devices performed about the 

same). 

Overall 

Equipment

Configuration 

x Equipment should be robust. 

x Device complexity of use should be secondary to function/performance. 

x Need good crew restraints for crew and test equipment. 

x Smaller probe will be harder to use in microgravity versus larger probes. 

x Need small probe for behind racks. 

x Probe guide wheel was nice; easy to use with ruler as guide. 

x Avoid spring-loaded wheels or a mechanical encoder—wheel push-down is 

difficult in microgravity (x2). 
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NDE Criteria Crew-member Observations 

x If you have a wheel encoder, must have small spring-force, but this force is 

not a show stopper. Attempt the mechanical encoder first and then have a 

backup plan ready if it does not work (time series?). 

x Wheel encoder is a “definite no-go.”

x A mouse optical encoder would work better than a mechanical encoder 

(x2). 

x Attempt a time-series scan instead of mechanical encoder. 

x Need arrows on probe to indicate beam scan direction and to indicate 

direction to move probe. 

x Suspect we would need a variety of probes. 

x If possible, consolidate one device to perform both USPA and EC scans. 

x Probe cumbersome with several wires—need integrated probe of encoder 

and transducer. 

x Avoid device with laptop and/or lots of extra parts. 

x The smaller the probe head the better. 

Crew Training: 

Ground

x Minimal hands-on, quick familiarity (x2). 

x 30 minutes ground training sufficient. 

x Train device menu/GUI; scanning is easy. 

x Show crew the device and parts. 

x All devices require about the same crew training. 

Crew Training: 

On-Orbit 

x On-orbit video training will be essential and effective for this operation 

(x4). 

x Have test samples on-orbit for crew to practice on prior to scanning 

damaged/suspect areas (x3). 

x Need reference points to get repeatable scans. 

x When the time comes to use this device, bite the bullet and do on-orbit 

training. 

ISS Interfaces x Like flexibility of all power options: batteries, hard-line power (alternating 

current (AC)/direct current (DC)) (x2). 

x Use standard laptop power bricks with a simple connector adapter. 

x Will need battery power for easier access to tight spaces without power 

cables. 

x Avoid flying a new power brick (x2). 

x Avoid AC/DC conversion. 

x Need video out (video graphics array) for real-time downlink of imagery. 

Crew Required x Recommend two crew members to be scheduled for NDE operations, 

similar to how reliability, maintainability, and supportability operations are 

scheduled today. 
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NDE Criteria Crew-member Observations 

x One crew member should be sufficient for most applications, but might 

need a second crewmember to assist, depending on location, distance, and 

setup (laptop?) (x3). 

x Scanning must be a single-handed operation (x2). 

x Cannot scan using two hands—one hand required to allow crew to brace 

themselves.

x Number of crew will depend on surface location and criticality. 

Overall 

Equipment

Size 

x Device, scanners, and accessories should be as small as practical to save 

stowage volume. 

x All devices seemed to consume the same amount of stowage (x2). 

USPA versus 

EC

x EC does not appear to help on ISS. 

x USPA gave an answer easier versus EC. 

x EC limited since cannot penetrate tape/leak repair patch. 

x Prefer U.S.—more capability. 

Other

Comments

x Does ground really have a plan for using the NDE-generated data? The 

information sent back to ground seems marginal for its intended purpose. 

How do you plan to use this information? Evacuate module? Evacuate

ISS? Install a better patch? How engineers use this data needs to be 

answered. 

x It would be appropriate to test the NDS hardware on a microgravity flight. 

x Technology seems sound; no show stoppers for use on ISS (x2). 

x We should have this technology on ISS. 
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Table J-2. Device-specific Crew Comments 

NDE Criteria Crewmember Observations 

Omniscan MX USPA x Easy setup and teardown. 

x Two “Start” buttons are confusing. 

x The default probe was too delicate and complex. 

x This device would benefit from an “easy menu”

option.

x Avoid compact flash cards (like universal serial 

bus (USB)). 

Omniscan MX EC x Same as Omniscan MX USPA. 

GE Phasor XS x Display seems small. 

x Has fewer buttons. 

x GUI menus a little cumbersome w/roller 

controls.

x This device would benefit from an “easy menu”

option.

x Would be hard to put Velcro on back due to 

large screws protruding from back. 

x Clunky box not really rugged for ISS use. 

x Similar in use to Omniscan. 
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NDE Criteria Crewmember Observations 

Sonatest Veo x Nice imagery, like pictorial image of damage; 

easy to understand. 

x Adapt probe for use on-orbit. 

x Seems easier to use but still has a troublesome 

encoder. 

x Spring on encoder okay. 

x Power cable sticks out from the back—will

interfere with setting the device on its back. 

x Easy to handle. 

x Good file and menu system, GUI easy. 

x Like lots of features, such as Ethernet capability, 

USB, and VGA out. 

x Preferred model (x2). 

UniWest ECS-3 x Laptop would allow more direct remote control 

from ground (black box). 

x Avoid using a laptop. 

x Current probe design too big and cumbersome 

(x3). 

x Cable out the back of probe will limit access on 

ISS. 

x Great imagery, “neat.”

x Would prefer two-dimensional imagery. 

x Too bulky, not really space/ISS ready (x2). 

Specific Findings and Recommendations: 

The majority of astronaut feedback centered on the operation of the NDE hand-held 

scanner/encoder. Several different techniques and encoder configurations were evaluated with 

mixed results. In all cases, a method to identify specifically where on a panel one was scanning 

needs to be developed. The use of rulers, tape, sharpie marks, and cameras are all potential 

solutions to help with reference points. This is especially needed if one hopes to get repeatable 

scan results. Most crew members felt that using a guide or ruler helped to increase scanning 

accuracy (see Figure J-2 below). 
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Figure J-2. Scanning using a Metal Ruler as a Guide 

A variety of probes will be needed on the ISS. A large probe is easier to operate but will not fit 

in confined areas of the ISS, such as behind racks and other secondary structures. Therefore, a

small probe will be required for these areas. Also, an integrated probe that includes a 

combination of encoder and transducer would be beneficial to develop—along with fewer 

wires—to minimize how cumbersome the probe is to operate in microgravity. The use of a 

wheel encoder was met with mixed reviews—some crew liked the wheel, while others said this 

was a “definite no-go.” The apprehension with a wheel encoder was due to the spring-force 

required to hold the wheel down onto the pressure shell—this would require a two-handed 

operation—a difficult task in microgravity since one hand is required to allow the crew to brace 

themselves while performing a scan. 

Most crew felt that an optical scanner would work better than the wheel/mechanical encoder. 

Alternatively, one could also use a time-series scan as a backup method, in case a mechanical 

encoder did not work in microgravity. See Figures J-3 through J-5 below for example probes 

and encoders used during the evaluation. 

Figure J-3. Ultrasound Array with Mechanical Wheel Encoder 
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Figure J-4. Large EC Probe with Mechanical Wheel Encoder 

Figure J-5. Large EC Probe 

Several crew members recommended that the NDE operations concept should mimic the HRF. 

The HRF system also uses crew-operated ultrasound scanners, but in addition, the output is sent 

to the ground and HRF engineers are able to provide feedback to the crew in real time. This 

would provide the crew with an immediate response from NDE experts as to the quality of the 

data the scans are providing. 

Training should be kept to a minimum during preflight training since there is only a minimal 

chance that crew will even need to operate this contingency-type equipment during their stay on 

the ISS. Once an event occurs that warrants the use of the NDE equipment (and all vehicle 

safing is complete), the crew can then train on the NDE equipment using on-orbit resources. The 

on-orbit resources should include video and computer-based training, clear procedures, and a few 

reference samples for crew to practice scanning. 

The majority of crew members felt that USPA devices seemed to provide more capability over 

EC devices, since USPA devices could scan sideways across material where access might be 

blocked by application of a pressure wall repair kit. A device with the ability to perform both 

types of scans might provide the most benefit to ISS. But, if the Crew Office were to select a 

single COTS NDE instrument to fly to ISS in the near future, it would be the Sonatest Veo. This 

instrument was a favorite of several astronauts due to the combination of device capability and 

good display imagery. 
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Specifically how this NDE-generated data will be used by ground engineers and management is 

an area that still needs significant work. The information provided by these instruments seems 

marginal for its intended purpose (but is still better than no information). What decisions can 

management be expected to make based on this data? How do you quantify this data? 

Finally, the Crew Office agrees that the NDE instruments examined during this evaluation have 

the potential to assist in understanding the type of damage sustained to ISS primary structures 

after an MMOD impact. The ISS Program should continue to develop this capability for use on 

the ISS. 

Table J-1. Test Samples

Standard 3 x 12 in. × 12 in. × 3/16 in. 

(flat). 

x Approximates primary 

Unites States on-orbit 

structure (USOS). 

x Circular pattern of 

machined partial throughholes covered with flexible 

patch. 

x Intravehicular activity 

(IVA), extravehicular 

activity (EVA) sides tested. 

x IVA side shown in photo. 

HD9820186 x 16 in. × 16 in. × 3/16 in. 

(flat). 

x Approximates primary 

USOS.

x MMOD penetration 

covered with dome rigid 

patch. 

x IVA side tested only. 

x IVA, EVA sides shown in 

photo.
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NDE Standard 7B x 12 in. × 12 in. × 3/16 in.

(curved).

x Approximates primary

USOS.

x Machined hole pattern on

one side, AL tape on other

side.

x IVA/tape side tested only.

x EVA side shown in photo.

NDE Standard 1B x 12 in. × 12 in. × 1/16 in.

(flat with ribs).

x Approximates Service

Module/Functional and

Cargo Module primary

structure.

x Ribs and calibration

standard notches and holes.

x IVA (smooth) side tested

only.

x EVA side shown in photo.
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Appendix K. Operations Assessment Report

ISS Operations Support Office (OSO) Evaluation of On-orbit Intravehicular Activity 

(IVA) Nondestructive Evaluation (NDE) Instrumentation 

NESC Assessment of NDE Equipment 

On-orbit Operations Assessment 

Mission Operations Directorate (MOD) 

Operations Support Officer Group – DX4 

Dan Perri, Bert Young, Chris Sinclair 

The first part of the operations assessment was to identify several generic qualities that OSO 

determines are important in the selection of tools to be used on-orbit. These criteria are then 

weighted according to importance. Each candidate NDE device was then evaluated by both 

OSO personnel and Astronaut Office representatives, using the evaluation criteria to grade each 

device against the others. The final results of this evaluation will serve as the MOD 

recommendation. 

These criteria are evaluated and graded, with the hope of narrowing down the selection to a 

single device that serves both the engineering and operations requirements and can be flown to 

the International Space Station (ISS). 

Testing Plan 

See the details of the evaluation methodology in Appendix J of this report.

Operations Evaluation Criteria 

Crew time for measurements: How much crew time is required to take measurements? The 

least amount of crew interaction is ideal. A score of 1 would be for something that required 

constant user attention and interaction to produce a measurement. A score of 5 would be 

something that crew could set and forget. 

Setup/tear down time: How much prep is required for the area to be scanned? Ideally, this 

equipment would require no setup and no surface prep activities before being ready to scan. Lots 

of preparation activities and assembly are not ideal but are in some cases unavoidable. 

NDE expertise/training required by crew: How much training does a user need in order to 

take a useable scan? Can a crew member operate the equipment, and collect engineering-usable 

data without any prior training? The user interface ease of use also falls into this category. Most 

likely, the crew will not receive ground training on the device, and at most will take a computerbased training (CBT) module on-orbit right before using the device for the first time. The less 

training needed to obtain a useable scan, the better. 
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Preventive/calibration/upkeep actions required: Does the tool require calibration before each 

run? Yearly calibration? No calibration at all? The less we have to fuss with the equipment 

during its lifetime, the better. 

Access requirements: Can this device make useful scans around an already installed pressure 

wall repair patch (rigid patch or flexible patch)? If it can’t create an image with a patch in place, 

it may not be viable for on-orbit use. Can it be used in limited access areas to make useful 

scans? 

ISS interfaces: How will the device interface with ISS? How does it send and receive data? 

What are the power requirements, and are those compatible with current ISS capabilities? It 

seems like most devices can be used on board with little to no modification. 

Number of crew required: Can this device be set up and operated by a single crew member? 

Size (storage and access impacts): From an operations perspective, the volume a piece of 

equipment takes up can be a large factor. This piece of equipment should move between all 

modules on the ISS with ease. It also must not take up too much space in stowage. 

Findings 

After testing, each device was assigned a score in each category using a five-point scale. The 

points were weighted and added to produce a final score for each device, which could be used as 

a quantitative measurement to make an operations recommendation. The operations 

recommendation should be used in conjunction with the engineering recommendation when 

deciding which specific device to fly to the ISS. 

Most of the devices require a similar amount of crew interaction to take measurements. They all 

require 100-percent crew attention to take measurements, so none of them were simple in that 

regard. Setup and teardown time for each device was also similar, but none were extremely 

difficult to set up. A couple of simple plug-in connections are all that each device requires, and 

usually each system requires a simple water spray as a coupling medium. The Uniwest system 

requires a second, dedicated laptop to make measurements, so it received a lower score than the 

others in this category. 

Expertise required by crew is the category where we started to see some differences between 

devices. Some devices had easy-to-navigate user interfaces, fewer buttons, and were easy to 

load configuration files; these received the highest scores in this category. Other devices had 

user interface menus that were difficult to navigate or didn’t have a good way to load 

configuration files. All of the devices could probably be trained using video/CBT along with 

some practice runs to get the onboard crew used to the operations. A common recommendation 

from the Crew Office was to mimic the Human Research Facility (HRF) group’s model for 

doing body ultrasound imaging, where the HRF scientists on the ground talk the astronaut 

through each activity in real time using live video and audio, and we believe each device tested 
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has the capability to be operated in this manner. Adopting this operations model could mean that 

crew members could get away with much less training to effectively take measurements. 

Each device uses a small, handheld sensor array attached to a mechanical wheel encoder. Only 

the ultrasonic phased array (USPA) devices were successful in generating images around the 

leak repair patches. USPA sensors can send a shear wave through the module wall, whereas the 

eddy current (EC) devices can only image straight down. The straight-down image is, therefore, 

ruined by the presence of both the dome rigid patch and the aluminum tape flexible patches. 

While EC imaging serves an important purpose in NDE assessment, from an ISS operations 

perspective, if the device can’t measure underneath a patch it should not be considered for this 

purpose. 

All devices have similar power requirements that can be accommodated on the ISS, just about all 

of them have the ability to export video using VGA connections, and most have an Ethernet 

connection or USB compatibility. 

In terms of number of crew required and overall device size, all devices were nearly identical. 

The Omniscan models have a slight edge since they are capable of doing USPA and EC scans by 

simply swapping a control module out of the back of the main unit, although this would require 

additional equipment. 

Recommendations 

The crew representatives had some useful comments and recommendations in regard to the 

coupling medium, sensor arrays, encoders, and operations/training concepts. For coupling 

medium, all crew said water would work great on-orbit, no need for ultrasound gel. The crew 

suggested that sensor arrays should be small but easy enough to hold with one hand. The 

encoders, which are used to record lateral motion of the sensor array as it slides across the 

surface and makes the scan, would ideally ditch the mechanical wheel encoder that most of the 

devices currently use. It was suggested that, prior to flying a device, engineers should look into 

providing a different type of encoder, either optical or laser, and attempt to integrate it into the 

sensor array so there are not quite as many separate moving parts for a zero-G crew to handle. 

As previously mentioned, crew also suggested mimicking the HRF operations model for 

conducting body ultrasound. OSO and the engineering team already invited some HRF 

representatives to come take a look at what was being done, and all agreed that it is a viable 

candidate for their operational philosophy. Some of the equipment they use to downlink video 

and data may also be compatible with the NDE equipment. This idea will need to be researched 

further. 

Grading each device based on the operations criteria yielded a numerical score for each 

candidate. The Sonotest Veo was the winner. It was also the initial favorite based on gut 

reactions from all crew members and OSO teammates. The Omniscan was a close second, due 

to its potential versatility (although new models will be unable to conduct ultrasonic and EC 
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measurements from a single unit), as well as its relative ease of use compared with the other 

units. 

There appeared to be no holdups from an operations perspective, as any of these NDE devices 

can probably be operated by crew members on-orbit for their intended purpose. The ISS simply 

needs a device that can take measurements underneath the dome rigid patch and flexible patch; 

the USPA sensors can do this, while the EC arrays cannot. Of the devices tested, the Sonotest 

Veo best met the criteria. 
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Appendix L. Engineering Assessment Report

8PSLXBTQFSGPSNFEVOEFS/"4"$POUSBDU//+*$
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Technical Assessment Report

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NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

375 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

376 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

377 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

378 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

379 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

380 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

381 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

382 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

383 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

384 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

385 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

386 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

387 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

388 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

389 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

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NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

390 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

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NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

391 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

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NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

392 of 396

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NASA Engineering and Safety Center

Technical Assessment Report

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NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

393 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

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NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

394 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

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NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

395 of 396

NESC Request No.: TI-12-00824
NASA Engineering and Safety Center

Technical Assessment Report

Document #:

NESC-RP09-00565

Version:

1.0

Title:

Independent Assessment of Instrumentation

for ISS On-orbit NDE

Page #:

396 of 396

NESC Request No.: TI-12-00824
REPORT DOCUMENTATION PAGE Form Approved

OMB No. 0704-0188

2. REPORT TYPE 

Technical Memorandum

 4. TITLE AND SUBTITLE

Independent Assessment of Instrumentation for ISS On-Orbit NDE

Appendices

5a. CONTRACT NUMBER

 6. AUTHOR(S)

Madaras, Eric I.

 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

NASA Langley Research Center

Hampton, VA 23681-2199

 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

National Aeronautics and Space Administration

Washington, DC 20546-0001

 8. PERFORMING ORGANIZATION

 REPORT NUMBER

L-20302 NESC-RP-12-00824

10. SPONSOR/MONITOR'S ACRONYM(S)

NASA

13. SUPPLEMENTARY NOTES

12. DISTRIBUTION/AVAILABILITY STATEMENT

Unclassified - Unlimited

Subject Category 16-Space Transportation and Safety

Availability: NASA CASI (443) 757-5802

19a. NAME OF RESPONSIBLE PERSON

STI Help Desk (email: help@sti.nasa.gov)

14. ABSTRACT

International Space Station (ISS) Structural and Mechanical Systems Manager, requested that the NASA Engineering and 

Safety Center (NESC) provide a quantitative assessment of commercially available nondestructive evaluation (NDE) 

instruments for potential application to the ISS. This work supports risk mitigation as outlined in the ISS Integrated Risk 

Management Application (IRMA) Watch Item #4669, which addresses the requirement for structural integrity after an ISS 

pressure wall leak in the event of a penetration due to micrometeoroid or debris (MMOD) impact. This document contains the 

appendices the final report.

15. SUBJECT TERMS

International Space Station; Nondestructive evaluation; MicroMeteoroid and Orbital Debris; NASA Engineering and Safety 

Center; ISS Risk Management Application

18. NUMBER

 OF 

 PAGES

401

19b. TELEPHONE NUMBER (Include area code)

(443) 757-5802

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Prescribed by ANSI Std. Z39.18

Standard Form 298 (Rev. 8-98)

3. DATES COVERED (From - To)

August 2012 - May 2013

5b. GRANT NUMBER

5c. PROGRAM ELEMENT NUMBER

5d. PROJECT NUMBER

5e. TASK NUMBER

5f. WORK UNIT NUMBER

869021.05.07.09.21

11. SPONSOR/MONITOR'S REPORT

 NUMBER(S)

NASA/TM-2013-218021/Volume II

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1. REPORT DATE (DD-MM-YYYY)

01- 07 - 2013