Wet Film Thickness Sensor/Device for Navy Platforms Navy SBIR FY2005.1 Sol No.: Navy SBIR FY2005.1 Topic No.: N05-068 Topic Title: Wet Film Thickness Sensor/Device for Navy Platforms Proposal No.: N051-068-0246 Firm: Systems and Materials Reserach Consultancy 19300 Crosswind Circle Spicewood, Texas 78669-5100 Contact: Alan Bray Phone: (512) 263-0822 Web Site: systemsandmaterials.com Abstract: Measuring dry film thickness (DFT) with microwave nondestructive evaluation (MNDE) to � mil accuracy has been demonstrated by SMRC's recently introduced K-band MNDE DFT tool. Extending to wet film thickness (WFT) measurement over unknown DFT requires a dual-sensor approach. X-band data for WFT over DFT in high solids paint (80% Zn) are promising - changes in microwave response as the paint dries are clear indications that SAPACS WFT measurements are feasible. In Phase I three X-band MNDE sensors will be built with standoffs from 4" - 6" with at least 1/2 mil accuracy in WFT over DFT, and 1/4 mil over metal substrates. SMRC proposes to build a detailed SAPACS WFT measurement model to support developing a design that minimizes systematic and random noise due to SAPACS motion and hull morphology. Sensor calibration data for WFT and DFT will be collected for single and multiple layers and types of hull paints. The X-band units will be combined into a dual-sensor system in Phase I Option as a pre-prototype SAPACS WFT MNDE measurement tool. The WFT measurement model will be continuously updated with DFT/WFT calibration and sensitivity data, making it a realistic, valuable design tool for Phase II development. Benefits: Automated paint systems are being considered by many manufacturers for a variety of reasons - as an example, as V-22 production ramps up it is critical that effective in-process measurement of WFT/DFT be employed to minimize paint buildup that can result in excess weight and increased probability of lightning strike damage. Automated paint systems have an important role in reducing environmental hazards - a major motivation for SAPACS/APACTS development for painting ship hulls. Control of WFT for these and similar systems requires very accurate feedback. With the introduction of SMRC's MNDE DFT tool in 2004 it became clear that the demand for accurate coating thickness measurements was significant in many industries. SMRC was recently awarded a 5-year Phase III IDIQ contract from NAVAIR for development and manufacturing of its MNDE technology. This award will put SMRC in contact with virtually every DoD NDE user, forming a larger market from which WFT systems for SAPACS will benefit. Two aerospace manufacturers have provided letters of support for MNDE WFT measurement. Return