Active Microwave Thermography Prototype Development for use as an In-Space Nondestructive Evaluation Tool

NASA has needs for sensors and nondestructive evaluation (NDE) techniques that can operate in-space to be able to sustain rapid, safe, and efficient space transport, sustainable living and working farther from Earth, and to support transformative missions and discoveries. In particular, NDE is needed to support in-space assembly, manufacturing, and refueling, advanced propulsion techniques, in situ resource utilization, and surface excavation and construction. NDE modalities for in-space applications and use are limited. In this proposal, Texas Research Institute (TRI) Austin and the Missouri University of Science and Technology (MST) propose the development of active microwave thermography (AMT) for use as an option for NASA as in-space NDE. Phase I will focus on demonstrating the system capabilities and mapping out a design for a Phase II prototype system that will be delivered to NASA upon the completion of the Phase II effort.

AMT holds significant importance for NASA and other federal agencies, particularly in the quality control processes related to aerospace and defense systems and to facilities in-space inspections. NASA can use AMT for assessing composite materials in aircraft, spacecraft, and defense-related components. This comprehensive approach contributes to ensuring the structural integrity and reliability of critical systems crucial for space exploration, space base construction and national defense. The precision and effectiveness of active thermography make it an indispensable tool for NASA and federal agencies involved in advancing and maintaining aerospace technologies, offering a sophisticated solution for inspecting a wide range of structures which increases the safety and performance of vital components. AMT offers advantages to NASA including non-contact and high speed, presented with a general setup and potential applications, especially in detecting defects like cracking, delaminations, porosity, etc. in aerospace and off-Earth structures. This NDE methodology is critical to NASA where in-space construction becomes crucial, necessitating quantitative and qualitative inspection tools. The relevance extends to various missions, including the Artemis program, where advancements in NDE technology are vital for addressing inspection difficulties in spacecraft like Orion and the Space Launch System. The latter, NASA's heavy-lift system, faces challenges in verifying components such as the friction stir weld on fuel tanks. Given NASA's aspirations for more extensive space exploration, the proposal underscores the importance of infusing Non-Destructive Evaluation (NDE) tools into NASA's systems for inspecting spaceflight hardware and structures in space. Tools proposed here are positioned as crucial enabling technologies to support continuous crew presence and facilitate long-duration missions. AMT holds significant importance for other federal agencies, particularly in the quality control processes related to aerospace and defense systems. Federal agencies like the Department of Defense and the National Institute of Standards and Technology (NIST), can use AMT for assessing composite materials in aircraft, spacecraft, and defense-related components. AMT can be used in inspection of concrete materials, offering a potential solution for inspections of critical infrastructure (such as bridges, buildings, and roads). Such adoption contributes to ensuring the structural integrity and reliability of critical systems crucial for space exploration, space base construction and national defense. The precision and effectiveness of AMT provides another NDE modality that can be used to provide quality control for a wide range of civilian infrastructure.

This is early/mid-stage (TRL 2) — 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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