Nondestructive Inclusion Detector

To address the Navy’s need for non-destructive technology for detection of inclusion content in high-grade steel components, Intellisense Systems, Inc. (Intellisense), proposes to continue, in Phase II, the development of its Nondestructive Inclusion Detector (INTER) system based on the innovative use of picosecond laser ultrasonic methods for generating high-frequency acoustic signals needed to detect micron-size inclusions. It uses machine vision algorithms for acoustic pattern recognition, enabling fast and accurate detection of defects. In Phase I, Intellisense successfully demonstrated the feasibility of the INTER system. We documented the system requirements, analyzed parameters affecting its performance, developed a system architecture, and conducted breadboard demonstration of the prototype. Based on Phase I results, we identified an application scenario where INTER can be used to detect defects, at high resolution (0.001”), in thin samples. In Phase II, Intellisense plans to advance, demonstrate, and evaluate the INTER system by incorporating several improvements to produce a mature INTER prototype, addressing the Navy’s practical applications. During the Phase II Base period, Intellisense will refine the INTER system design, develop the primary hardware and software modules, including the design of a mechanical package for the INTER system. Intellisense will then test the INTER prototype on production size and grade blind steel samples to demonstrate non-destructive defect detection down to 0.001” size on in-process (partially finished) and post-production components. During the Phase II Option 1, Intellisense will further customize the INTER system to address the practical applications in the intended environments such as steel manufacturing sites, component production sites, and repair facilities, and prepare the software and hardware subsystems for transition to INTER product development and low-rate production. Final testing will be perform that would include on-the-ground evaluation in fleet/repair/production environments; INTER will be also evaluated by first users such as GE Aviation Engines.