Lightweight High-Energy X-ray Source for In-Space Nondestructive Evaluation

Long-duration space operation require novel convenient methods of in-space manufacturing. Additive manufacturing (AM) is ideal for the space industry, where part production is low volume and highly customized. However, in order to be fully implemented, the AM components must be inspected for seeing hidden flaws via non-destructive evaluation (NDE). In order to enable accurate NDE of in-space fabricated objects by radiography or computed tomography methods, the MeV-grade X-ray source is required. Although electron linacs represent a mature technology, with an established industrial base, at the present there is no state-of-the-art device suitable for in-space applications. In this project, we will develop a hand-portable X-ray source based on a 2.0 MeV electron linac. The mass and size reduction will be achieved thanks to the operation in Ku-band regime enabled by the revolutionary split linac fabrication technology and novel Marx modulators. In Phase I, we will design the modulator, the X-ray conversion system, and optimize the layout of peripheral components to keep the total weight within 50 lbs. In Phase II, we will build and test the full linac system and fully demonstrate the designed beam and X-ray parameters. This project will develop a hand-portable X-ray source based on an electron linac with 2 MeV energy for Nondestructive Evaluation of components in a space environment. The key innovation is operation of the linac in Ku-band RF frequency, which wasn’t employed before due to the lack of RF sources and extremely tight fabrication tolerances. We will resolve these problems thanks to the use of compact low-power Ku-band magnetrons, a revolutionary approach to fabricate the accelerating waveguide through the split accelerating structure technique, and novel design approach for Marx modulator high-voltage power supplies. This project represents the first attempt to equip future space flight missions with a tunable and directional source of relativistic electrons and X-ray for many critical applications.

The proposed device can be used for radiographic analysis of 3D printed parts, including non-destructive radiography, back-scattered imaging and computed tomography of critical components, lunar transport vehicles and spacecraft shielding for a wide range of NASA missions. A hand-portable source of high-energy X-rays can replace radioisotopes such as Cs-137 and Ir-192 in field radiography, security and medical applications. In addition to filling a market need, it will reduce the risk of accidents and diversion of radioactive materials for terrorist purposes.

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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