Probability of Detection and Validation for Computed Tomography Processes for Additive Manufacturing (21-RD-284)

X-ray computed tomography (XCT/CT) is a widely used nondestructive evaluation (NDE) method for quality control and post-build inspection in additively manufactured (AM) components. AM practitioners increasingly recognize the limitations of such NDE methods and the need to validate the capability of these methods on an ongoing basis. Automated, metallography-based serial sectioning offers a reliable method to establish ground truth data on the flaw populations as well as microstructural variations of AM components. UES proposes a project aimed at establishing comparison methods and workflows for validating CT with ground truth from serial sectioning, and developing probability of detection (POD) curves for multiple materials and defect types. The knowledge gained from these efforts will inform CT scan strategies for improved flaw detection in AM components, evaluate flaw detectability in CT using serial sectioning as a ground truth comparison, and quantify the risk of the flaws absent from the CT data sets. In addition, improving the capabilities of an automated defect recognition (ADR) algorithm can improve NDE throughput.

NASA experimenting with AM across a broad spectrum of applications and projects. AM has potential applications in the Lunar and Lagrange FabLabs, as well as the Mars Multi-Material FabLab for self sustainment at remote destinations Improving AM via NDE has positive implications for 100% inspected directives on Orion missions.

Reliable NDE/NDI of completed components remains a barrier to wider utilization of AM components. Limitations in the availability of probability of detection (POD) data will drive wider adoption of AM. Validated interest in improving automated defect recognition algorithms.

This is a mature technology (TRL 7) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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