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In Situ Inspection of Additive Manufactured Metallic Parts Using Laser Ultrasonics

Award Information
Agency: Department of Defense
Branch: Navy
Contract: N68335-15-C-0260
Agency Tracking Number: N15A-008-0134
Amount: $154,871.00
Phase: Phase I
Program: STTR
Solicitation Topic Code: N15A-T008
Solicitation Number: 2015.0
Solicitation Year: 2015
Award Year: 2015
Award Start Date (Proposal Award Date): 2015-06-15
Award End Date (Contract End Date): 2016-09-30
Small Business Information
2520 W. 237th Street
Torrance, CA 90505-5217
United States
DUNS: 033449757
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 Marvin Klein
 (424) 263-6361
Business Contact
 Reuben Sandler
Title: Materials Engineer
Phone: (424) 263-6305
Research Institution
 Penn State ARL
 Barbara Johnson
P.O. Box 30
State College, PA 16804-0030
United States

 (814) 865-0307
 Nonprofit College or University

Additive manufacturing (AM) is a very promising technique for rapid, low-cost production of aircraft parts directly from a CAD file. AM is especially appealing for complex parts that would be costly or impossible to fabricate by machining or casting. At the current time there are no reliable, cost-effective techniques to qualify the finished parts. Several government studies have noted this gap and urged increased efforts to develop improved techniques for part qualification. In this project we will demonstrate the feasibility of applying laser ultrasonic testing to evaluate each deposited layer in real time during the build process. This in-line inspection has the benefit of part qualification layer-by-layer, ensuring finished parts that require no further testing. In Phase I we will team with Penn State Applied Research Laboratory, which will supply samples with well characterized defects and give general technical guidance. We will then optimize the beam configuration for the best sensitivity to these defects, and also develop signal processing algorithms to enhance the defect detection threshold and collect size information. In Phase II a prototype in-line inspection system will be developed and tested on a production machine.

* Information listed above is at the time of submission. *

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