Use of Phased-Array Ultrasound for Flaw Detection in Composites

The performance advantages of composite rocket motor cases and exit cones have been demonstrated. However, non-destructive evaluation (NDE) of composite missile components can offer significant challenges, due to the porosity levels which may beencountered in these materials, and potentially small critical defect size. The most popular current NDE technique, X-ray, is not field portable, requires an extensive investment in capital equipment and presents worker safety hazards. In this Phase I,program Foster-Miller will work with a team consisting of RD Tech and Boeing Rocketdyne to evaluate the capabilities of phased-array ultrasound to detect of range of defects in composites structures for MDA missile applications (initial focus on ceramicmatrix composites for THAAD). The proposed program will determine whether phased-array NDE has the capabilities to meet the MDA requirement for inspection of the composite missile structures. If successful, this Phase I program will indicate a EMRL of 2for this technology, and serve as a basis for assembly of a commercial portable phased-array NDE inspection system which can be ready for use in an operational environment at the end of Phase II (EMRL 3). (P-030172) The proposed technology would beanticipated to have a high level of applicability for NDE of a wide range of DOD and commercial composite structures and components, including DOD and commercial aerospace, automotive, civil infrastructure (composite or composite reinforced bridges andoverpasses), and sporting goods manufacture. The Foster-Miller program team, which includes Boeing Rocketdyne and RD Tech, provides a clear path to use of the technology in missile defense systems.