Advancement of CryoUltrasonic Testing for Inspection of Aerospace Components

TECHNOLOGY AREAS: Materials The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 3.5 of the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. OBJECTIVE: The objective of this topic is to advance the readiness of CryoUltrasonics technology to enable nondestructive evaluation of complex-shaped components. End state performance should meet a ultrasonic testing frequency threshold of 2 Megahertz, and objective of 10 Megahertz, for representative aerospace components. Testing performance should be assessed using known features such as range of differently sized flat bottom holes (FBHs) to sizes as small as #1 (1/64 inch). At a minimum, the activity should demonstrate freezing, testing and analysis of at least two representative aerospace components in ice- or ice-based composites. One desired demonstration is to freeze disk-shaped components at least 24 inches in diameter (objective 36 inches in diameter), and as a separate demonstration, freeze-test-and-analyze components with complex internal geometry such as curved channels or vanes. An additional desire is to include representative components for testing ranging from lightweight-to-dense alloys (e.g., Aluminum, Titanium, and Nickel-based alloys) and composites. DESCRIPTION: CryoUltrasonic testing is an emerging method for nondestructive evaluation of complex-shaped components of metallic alloys and high performance composites [1]. The method involves encasing the component in an ice- or ice-based composite to more closely match the acoustic properties of the component. Compared to conventional immersion ultrasound in water, this methodology provides both improved transmission of sound and reduced refraction at component-ice interfaces [1], allows for a larger critical angle at component-ice interfaces thus facilitating inspection of highly inclined and curved surfaces [1,2,3,4], has relative insensitivity to rough interfaces like those produced by metal Additive Manufacturing processes [3], and can transform the inspection article into a simple solid shape [1,2,3,4]. These attributes are beneficial for both conventional and Additively Manufactured components that cannot be easily inspected using mature nondestructive evaluation methods such as immersion ultrasound testing or x-ray Computed Tomography. However, the benefits of Cryo Ultrasonic inspection for structural components are not yet fully realized. It is desired to enhance this laboratory-based methodology to enable capability demonstration(s) on representative aerospace components with surrogate flaws as small as a 1 Flat Bottom Hole. In particular, innovative approaches are sought to reduce the total cycle time for preparation, testing and analysis to a few hours, while also enabling freezing of parts up to 36 inches in diameter while maintaining excellent acoustic properties. PHASE I: As this is a Direct-to-Phase-II (D2P2) topic, no Phase I awards will be made as a result of this topic. To qualify for this D2P2 topic, the Government expects the applicant(s) to demonstrate feasibility by means of a prior Phase I-type effort that does not constitute work undertaken as part of a prior SBIR/STTR funding agreement. The applicant(s) is required to provide detail and documentation in the Direct to Phase II proposal which demonstrates accomplishment of a Phase I-like effort that includes demonstration of Cryo Ultrasonic Testing on sample(s) with surrogate or known defects that demonstrate feasibility for key processes in CryoUltrasonic workflow: freezing of the sample, ultrasonic testing (at frequencies of at least 2 megahertz or higher), and analysis demonstrating detection of the defect. The applicant(s) should have defined a clear, immediately actionable plan with the proposed solution. Letters of support from potential collaborators/stakeholders is encouraged. PHASE II: Under the Phase II effort, the awardee(s)shall sufficiently develop the CryoUltrasonic Testing technology to provide capability demonstration(s) on representative aerospace components that contain surrogate defects as small as a 1 Flat Bottom Hole. Identification of issues and or business model modifications required to further improve product or process relevance to costs, availability, or safety, should be documented. PHASE III DUAL USE APPLICATIONS: The awardee(s) will pursue commercialization of the various technologies developed in Phase II for transitioning expanded mission capability to a broad range of potential government and civilian users and alternate mission applications. Direct access with end users and government customers will be provided with opportunities to receive Phase III awards for providing the government additional research & development, or direct procurement of products and services developed in coordination with the program. REFERENCES: 1. Simonetti, F., et al. "Cryo-ultrasonic NDE: Ice cold ultrasonic waves for the detection of damage in complex-shaped engineering components." IEEE transactions on ultrasonics, ferroelectrics, and frequency control 65.4 (2018): 638-647. 2. Simonetti, F., and M. Fox. "Experimental methods for ultrasonic testing of complex-shaped parts encased in ice." NDT & E International 103 (2019): 1-11. 3. Simonetti, F., and M.D. Uchic. "Equiaxed Polycrystalline Ice for Ultrasonic Testing of Solids." Physical Review Applied 18.1 (2022): 014034. 4. Simonetti, F. "Cryo-ultrasonic testing of curved components." NDT & E International 137 (2023): 102835. KEYWORDS: CryoUltrasonic Testing; Nondestructive Evaluation; Nondestructive Inspection; Phased Array Ultrasonic Testing