A Compact, Low Cost, Handheld Sensor for Non- Destructive Material Case Depth Verification Navy SBIR FY2010.2 Sol No.: Navy SBIR FY2010.2 Topic No.: N102-141 Topic Title: A Compact, Low Cost, Handheld Sensor for Non- Destructive Material Case Depth Verification Proposal No.: N102-141-0903 Firm: AlphaSense, Inc. 470 Century Blvd. Wilmington, Delaware 19808 Contact: Pengcheng Lv Phone: (302) 998-1116 Web Site: www.alphasense.net Abstract: In this proposal, AlphaSense, Inc. and the Center for Non-destructive Evaluations at Iowa State University detail the development of a compact, low cost handheld sensor for non-destructive material case depth verification. The key innovations of this proposal include the following: a) case depth evaluations based on electromagnetic property measurements, b) a model based alternating current potential drop (ACPD) method to obtain the electromagnetic property of case hardened parts, c) the design and implementation of miniature ACPD probes, d) high throughput scanning of case depths using a frequency hopping technique, and e) the implementation of a compact, low cost handheld measurement system with a microcontroller. With such innovations, the merits of the proposed sensor and its advantages over other techniques are listed below: a) Rugged, compact and low cost, b)Capable of measuring a wide variety of hardened parts with complex shapes, c) High sensitivity and large dynamic range, d) High throughput measurements, and e) Easy-to-use model based approach. Benefits: . The outcome of this research is coupled to a very clear commercialization path. The outcome of this research is coupled to a very clear commercialization path. The proposed sensor technology can be used in a wide variety of military and civilian applications. For military applications, the proposed sensor can be integrated into many DoD programs, including the NAVAIR rotorcraft programs (e.g. PMA-299 H-60 multi-mission helicopter program and PMA-261 H-53 heavy lift helicopter program) and the Air Force's Common Vertical Lift Support Platform (CVLSP) program. The sensor allows high throughput and non-destructive measurements of case depths in hardened rotorcraft parts, including the gears, bearings, splines and rotorshafts, etc. Therefore, the proposed sensor can lead to substantial time and cost savings to assure the quality and product consistency of those critical components. Additionally, the proposed sensor can find applications in many other programs dealing with aircraft gas turbine engine components, ground vehicles and firearms development, as case hardening is routinely used to enhance the surface properties and fracture toughness of many critical components. Besides the military applications, commercial applications of the proposed sensor include inspection and quality assurance of gears, bearings, splines, crankshafts, tracks and drill pipes used by construction, mining, automobile and commercial aircraft equipment manufacturers. Potential end users may include the military system integrators (e.g. Boeing, Sikorsky, and Lockheed Martin), bearing and gear OEMs (Timken), construction and mining equipment manufacturers (Caterpillar and Eaton), automaker (General Motor), and commercial helicopter manufacturer (Bell Helicopter) etc. Return