Nondestructive Internal Flaw Detector

To address the MDA need for an innovative, non-destructive evaluation (NDE) process for rapidly evaluating the suitability of 3D printed production metal parts, Intellisense Systems, Inc. (Intellisense) proposes to develop a new Nondestructive Internal Flaw Detector (NEILL) system based on ultrasonic thermography augmented by advanced signal processing optimized for application on 3D printed metal parts. Specifically, the innovative use of thermography along with laser ultrasonic methods enables a noncontact, non-destructive method for evaluating the defects in 3D printed metal parts. In addition, the system uses enhanced image processing to process and improve defect extraction allowing determination of location, size, and depth of voids and intra-granular impurities. Correlating the ultrasonic information and thermal information results provides a better understanding of the overall internal structure of the target. As a result, the NEILL system offers accurate, non-destructive inclusion of an integrity assessment in the additive manufacturing process to allow corrective actions to be performed to prevent failure of a part in service and to certify parts for use either during or immediately after manufacturing. During Phase I, Intellisense plans to assemble and test a proof-of-concept prototype to demonstrate feasibility of the NEILL system detecting internal voids and defects in common aerospace material that result in lower than expected failure resistance or fatigue life. The results will be documented and correlation between NDE results and ultimate strength will be described along with plans for Phase II. In Phase II, Intellisense will demonstrate the ability to detect internal flaws in multiple large complex parts with assorted internal flaws to demonstrate the correlation between NDE results and the ultimate strength at failure with high statistical confidence, as well as the ability to validate the quality of prototype flight hardware with the same confidence as CT scans. Approved for Public Release | 20-MDA-10643 (3 Dec 20)