Comparative Evaluation of Crack-like Defects in Additively Manufactured Parts (AM Flaw)

Completed TRL 3 (started at 3, targeting 4)

Description

As we explore the effectiveness of different Non-Destructive Evaluation (NDE) methods for Additively Manufactured (AM) parts, such as radiography, ultrasound, dye penetrant, etc., a few more fundamental questions have not been clearly answered. Broadly speaking, we do not understand if a crack in an AM part imparts a different NDE response than one in a traditional part. For this study, we aim to understand the difference in NDE response between AM and conventional manufactured parts. In particular, we aim to assess the NDE response as a function of surface topology (roughness/form differences, build orientation, etc.) and also as a function of internal grain structure.

Additive coupons will make use of industry standard 3D printing approaches and using materials relevant to NASA missions. Natural flaws will be induced in coupons using high cycle fatigue, in particular surface breaking cracks. Parallel sets of coupons will be made for each aspect of the study, i.e. a set to understand surface roughness and one for grain structure.

Benefits

Gain a more fundamental understanding of AM’s influence on NDE signal response.
Establish process(es) for creating flaw coupons for future AM POD studies.
Help analysts and PDLs better understand the risk of flying an AM production part.
Help NDE community better define detectability limits for AM parts and possible knockdown factors for 5009/Table 1.

Details

Technology area	Materials, Structures, Mechanical Systems, and Manufacturing > Manufacturing > Nondestructive Evaluation and Sensors
Program	Nondestructive Evaluation Program (NDE)
Lead organization	Goddard Space Flight Center, Greenbelt, MD
Start date	2019-10-01
End date	2021-09-30

Project contacts

Listed on TechPort itself — the most direct way to ask about this specific project.

Justin S Jones — justin.s.jones@nasa.gov
Antonio Moreno — antonio.moreno@nasa.gov
Nathan A Smith — nathan.a.smith@nasa.gov
Stephen W Lebair — stephen.w.lebair@nasa.gov

How to get involved

This is early/mid-stage (TRL 3) — 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.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.