Multi-sensor Layered Composite Health Testing System (MULCH)

The U.S. Navy uses is increasing their use of composite materials on both surface and undersea vehicles. Unfortunately, there is currently no nondestructive evaluation (NDE) system that can reliably detect, identify, and locate damage in these thick materials without removing the materials and the outside coating. To meet the Navy need for such an NDE system, Luminit Government Services, LLC (LGS), proposes to develop a unique Multisensor Layered Composite Health testing (MULCH) system. The MULCH combines a set of independent NDE sensors, such as ultrasonic imaging processed by digital image correlation with microwave imaging and thermography, to rapidly, accurately locate and measure defects and water intrusion. Phase I will consist of surveying available testing technologies and machine learning classification algorithms, fabrication of laboratory-based tests for the most-promising test methods, and demonstration of a prototype exemplifying any improvements stemming from combination of NDE technologies, ending at technology readiness level (TRL) 4. In Phase II we will further develop the prototype into a robust, portable system capable of detection and characterization of porosity, voids, delamination, moisture intrusion, and evaluation of bond-line integrity, ending with a field-testable prototype at TRL 6.