Multi-Sensor Prototype for Non-Destructive Corrosion Evaluation and Characterization

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Advanced Materials OBJECTIVE: Develop a multi-sensor unmanned aerial vehicle (UAV) system that can assess the condition of a guy wire in situ (in place/position) and identify degradation and potential areas of repair needs before major damage has occurred. DESCRIPTION: Current UAVs include visual cameras, making visual inspection easily attainable, but cannot view below the surface. Ultrasonic inspection of corrosion on cables requires direct contact with the surface along with the application of a water-based gel, neither of which are easily adapted into a UAV for cable inspection [Refs 1, 2]. Infrared (IR) thermography cannot view more than a few centimeters below the surface and may require high temperatures to provide useful data [Ref 3]. X-ray fluorescence requires extra safety considerations given the outdoor environment. Eddy current testing requires direct contact or near direct contact [Ref 4]. Magnetic flux analysis may require large magnetic fields to provide useful results. The desire is for a mobile platform that combines multiple sensors and measurement/analysis technologies to provide subsurface corrosion detection along with surface corrosion characterization up to hundreds of feet away from the operator. Basic requirements: Travel height above ground: 1000ft (T), 1500ft (O) Travel length in one direction: 1500ft (T), 2300ft (O) PHASE I: Develop a concept for a UAV system with a multiple Nondestructive Evaluation (NDE) sensor configuration to characterize corrosion and identify areas of further interest. Demonstrate the feasibility of the concept. Prepare a report to ONR / NIWC Pacific on system concept design(s) and sensor output modeling and prepare a Phase II production and testing plan. PHASE II: Construct a prototype UAV system and assess the accuracy of the corrosion characterization. Provide a report that documents the design options for a prototype system that includes results of operations and type/level/fidelity of corrosion inspection performance. Provide a Phase III plan to ONR 35 / NIWC Pacific for prototype evaluation. Produce a prototype system for NIWC Pacific evaluations. PHASE III DUAL USE APPLICATIONS: Refine the UAV system and demonstrate corrosion identification, characterization, and analysis. Deliver a UAV system to NIWC Pacific and provide a report containing designs and test data to ONR / NIWC Pacific. The development of a more available option for UAV corrosion assessment would enable remote inspections for a variety of commercial infrastructure applications. Current commercial infrastructure (wind turbine blades, ship hulls, etc.) makes use of a variety of sensor outfitted unmanned systems (UxS); however, none are currently optimized for stand-off, large scale corrosion inspection to the best of our knowledge. Most of the existing commercial options are predominantly fee for service options, vice a complete, off-the-shelf hardware/software asset that is available for procurement. REFERENCES: Zhang, D.; Watson, R.; Dobie, G.; MacLeod, C. and Pierce, G. Autonomous Ultrasonic Inspection Using Unmanned Aerial Vehicle. 2018 IEEE International Ultrasonics Symposium, pp. 1-4. 10.1109/ULTSYM.2018.8579727 Hernandez-Salazar, C.D.; Baltazar, A. and Aranda-Sanchez, J.I. Damage Detection in Multi-wire Cables Using Continuous Wavelet Transform Analysis of Ultrasonic Guided Waves. 2009 IEEE Electronics, Robotics, and Automotive Mechanics Conference, pp. 250-255. 10.1109/CERMA.2009.65 Kerdoncuff, H.; Lin, W-I. and Wacker, L.J. Spectroscopic techniques for corrosion detection using drones. Danish National Metrology Institute, Report DFM-2017-R005, Ver. 1.01, 2017. Mathey, R. and Clifton, J. Review of Nondestructive Evaluation Methods Applicable to Construction Materials and Structures. National Bureau of Standards Technical Note 1247, 1988. KEYWORDS: Corrosion identification; unmanned aerial vehicle; UAV; infrared imaging; eddy currents; magnetic flux; ultrasonic testing; non-destructive materials