Laser Ultrasonic Testing for In-Space Welding Environments

NASA has expressed a key need for the development and hardening of in-situ instrumentation to support ground-based thermal vacuum chamber testing in which the effectiveness of welds may be studied in a space analog environment, in preparation for inspection during space-capable laser beam welding. In-situ laser ultrasonic inspection has not previously been used to meet this need. This alternative technology has a long history of successes in demonstrating its capability to identify and characterize welding flaws and defects with submillimeter dimensions in-situ, but only in terrestrial environments. Current imaging technologies are limited to flaws and defects apparent at the surface, while current ultrasonic and X-ray technologies are generally not practical in space environments. We propose to adapt a terrestrial laser ultrasonic inspection system for in-situ use in space analog environments. In Phase I we will perform laser ultrasonic inspections of relevant weld samples in our laboratory, and study space analog environments, to arrive at inspection system adaptations that will meet this need. We anticipate demonstrating flaw detection in our laboratory, developing initial designs and test plans for a suitable prototype system to test in space analog environments in Phase II, and developing an initial design for an in-space laser ultrasonic system for detection of critical flaws in welds.

The proposed technology has great potential in multiple NASA applications, particularly in the realms of additive manufacturing and nondestructive evaluation. For example, the In-Space Manufacturing (ISM) Project, which focuses on developing in-space manufacturing capabilities to reduce reliance on launching spare parts from Earth. LUT can be a critical tool for in-line inspection of parts produced in space, ensuring their quality and reliability in the harsh conditions of spaceflight. It can also be used in Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project which is pioneering the use of additive manufacturing to develop new alloys and 3D-printed rocket components. Furthermore, the In-Situ Characterization and Inspection of Additive Manufacturing project could leverage LUT to detecting defects in early stage to reduce material waste and improve part quality by identifying issues such as porosity and cracks as they occur. The proposed technology could also be applied to the Shuttle Orbiter Nondestructive Inspection program, where it can make monitoring and inspecting of the structure health of the shuttle after each obiter flight much more efficient and accurate. The proposed technology also has wide-ranging applications beyond NASA, extending to industries such as commercial aerospace, manufacturing, energy, and automotive. In the commercial aerospace sector, LUT can be used for inspecting composite aircraft components, adhesive bonds, and turbine blades, significantly reducing inspection time while enhancing safety and reliability. In manufacturing, it will enable real-time monitoring of processes like additive manufacturing and steel tube production, detecting defects such as porosity and ensuring precise wall thickness measurements. The oil and gas industry can leverage LUT for detecting cracks in pipelines and performing online thickness measurements, ensuring infrastructure safety. In the nuclear sector, it can inspect reactor components under hazardous conditions where traditional methods are impractical. The automotive industry can use LUT to evaluate lightweight composites and welds, improving vehicle durability and efficiency. Additionally, government agencies (e.g. DOT and DOE) can apply LUT for inspecting critical infrastructure and materials, ensuring compliance with safety standards. Its multi-material compatibility, non-contact, high-speed, and high-precision capabilities make it a transformative technology across multiple markets, driving innovation and enhancing operational efficiency.

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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