Adaptive, Velocity-Sensing Receiver for In-Line Inspection of Additive Manufactured Aerospace Parts

An increasing number of safety-critical aerospace components are being produced by additive manufacturing (AM). Specific NASA missions with AM components include the Artemis Program's Orion Spacecraft and the Space Launch System. Reliable qualification of finished AM parts is needed for safety-critical aerospace applications, as only fully inspected parts can be certified for flight. In a previous NASA SBIR project, we demonstrated the feasibility of meeting this need by applying laser ultrasonic testing (LUT) for nondestructive evaluation of each AM deposited layer in real time as it is formed. This in-line inspection qualifies the part layer-by-layer, directs defect removal during the manufacturing process, and ensures qualified finished parts that require no further testing. In this project we are developing a new type of laser ultrasonic sensor that will greatly improve the state of the art in inspection performance, leading to improved suppression of mechanical and acoustical disturbances, and also enabling the implementation of a simpler and more agile beam setup and probe design. Such performance improvements will escalate the motivation for AM stakeholders to include the use of LUT in in-line inspection. The Phase II tasks are anticipated to result in enhanced signal processing algorithms and software, a more agile probe, faster adaptive crystal response, and effective integration of LUT in-line inspection into a commercial AM machine.

Additive manufacturing (AM) is finding broad applications by NASA and its contractors for the fabrication of high-value, safety-critical components. The enhanced in-line AM inspection system described in this project will enable the production of fully qualified AM parts to be used in the Orion Spacecraft and the Space Launch System. The technology is aligned with the NASA Space Technology Roadmaps, and addresses the needs described in the recent NASA memorandum "Nondestructive Evaluation of Additive Manufacturing."

In addition to the space industry, other industries that are adopting AM include military and commercial aviation, and automotive and consumer products. Aircraft engine suppliers have been investing heavily in capacity for AM parts manufacturing. Key high-value components such as injection nozzles are found multiple times in a turbine engine. The use of AM will reduce engine weight and cost.

This is early/mid-stage (TRL 6) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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