In-Process Cure Monitoring of Specialty Material Coatings

TeraMetrix proposes a SBIR STTP CRP project to perform all of the development, on-aircraft validation and transition planning tasks to implement an automated robotic non-contact time-domain terahertz (THz) specialty coating thickness inspection for the F-22 inlet ducts. The proposed THz measurement system will utilize existing spray robots to automatically position the THz sensor, replacing a slow manual quality assurance process. The F-22 requires an improved capability and more reliable and accurate method of verifying inlet specialty coating thickness to tight tolerances. To address the inaccuracy and unreliability with the baseline thickness measurement system, this effort will evaluate, mature and demonstrate an improved specialty coating thickness capability. A fundamental THz coating thickness measurement technology has been developed and is capable of accurately and repeatably taking thickness measurements of specialty coatings. Specifically, the THz technology enables a non-contact, nondestructive capability to measure the coating thickness to rapidly determine if it meets thickness quality assurance and specification requirements. The THz thickness measurement technology was originally designed to address F-35 inlet coatings specifications during manufacturing, but the technology can be extended to other advanced weapon material systems coating processes, such as those incorporated on F-22 during refurbishment.