Thermal Protection Systems Nondestructive Evaluation Tool

Based on the successful feasibility demonstration in Phase I, Physical Optics Corporation (POC) proposes to continue the development of a novel Thermal Protection System Nondestructive Evaluation Tool (THRON), which addresses NASA's need for evaluation of lightweight rigid and/or flexible ablative materials, and provides noncontact, one-sided in situ operation for accurate detection, identification, and precise spatial localization and measurements of internal and surface defects/voids, and evaluation of bondlines and in-depth integrity of such materials and also large-area multilayer thermal protection system (TPS) structures with complex geometries. THRON is based on POC-patented X-ray Compton imaging tomography and POC-patented apodized coded aperture X-ray imaging optics, substantially modified and optimized to meet NASA's requirements. The THRON Phase I prototype demonstrated excellent potential for detection and spatial localization of defects/voids with dimensions <6 mm by 6 mm by 6 mm, and bondline defects <12 mm by 12 mm by 200 μm in TPS material and structures. At the end of Phase II, POC will perform a technology readiness level (TRL)-6 demonstration of THRON in POC's X-ray lab and/or at NASA facilities, and will deliver to NASA a working engineering model of an effective NDE tool.

The primary NASA application of the proposed THRON is a compact NDE system that can be used for noncontact, one-sided in situ evaluation of structural integrity of TPS spacecraft material and structures, with the capabilities of accurate detection, identification, and spatial localization of internal and surface defects (cracks, voids, delaminations, porosity, and inclusions), and evaluation of bondlines and in-depth integrity of lightweight, rigid, and/or flexible ablative materials and large-area multilayer TPS structures with complex geometries. Additional NASA applications include in situ NDE/NDT of large-area nonuniform multilayer aluminum/titanium/composite structures with complicated geometry used in the development of advanced aircraft and spacecraft, providing accurate identification, localization, and measurements of all types of internal and surface defects.

Military applications of THRON will include in situ NDE/NDT of large-area, nonuniform, multilayer, aluminum/titanium/composite structures with complex geometries, and also combined polymeric, ceramic, and metal matrix composite structures for U.S. Air Force, Navy, and Army aircraft. THRON-based systems (with minimum modifications of THRON) will also be used for NDE/NDT of airplane, helicopter, and missile parts containing electronics, mechanical components, propellants, explosives, etc., to detect defects and verify integrity. THRON-based systems can be incorporated by the U.S. Air Force, Navy, and Army as a reliable, rapid, robotic, easy-to-use NDE/NDT system. Potential DHS applications include the detection of vehicle-borne contraband, drugs, and explosives. The commercial applicability of THRON includes its use for in situ NDE/NDT of large-area nonuniform multilayer aluminum/titanium/composite structures with complex geometries in aging and modern commercial aircraft, spacecraft, light marine vessels, and any application requiring defect detection for multilayer ceramic, composite, metallic, and plastic nonuniform structures.

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