Challenges in performing Integrated, Correlated Visual Evaluation and associated Material Characterization (NDE 4.0) for Failure Analysis of Spacecraft Propulsion System Components

Design of Spacecraft propellant system components are critical in nature as the material must sustain its integrity in corrosive propellant environment, under fatigue loads for mission of 5-12 years with optimum factor of safety. Any deviation observed in such components leads to catastrophic mission failure. Despite detailed review mechanism and quality protocols, some random component failures can occur during system level testing. Failure analysis is challenging as the components are of miniature size (thickness 80µm) and limited access (Bore Ø 1.9mm) to obtain prima-facie details. Also, each failure is unique as no failure-precedence is available. An exhaustive–cum-integrated component evaluation and failure analysis in line with Non-Destructive Evaluation 4.0 (NDE 4.0) is ensured by incorporating Automation, digitisation, data acquisition, Correlation, integration, high resolution, non-contact, enhanced probing/NDE detection capabilities, enabling corroborative integrated studies with material NDE tools. The comprehensive NDE analysis with interdependent visual material tools provides forward-feed design input for performing NDE reliability studies.