In Situ Inspection of Additive Manufactured Metallic Parts Using Laser Ultrasonics Navy STTR FY2015.A Sol No.: Navy STTR FY2015.A Topic No.: N15A-T008 Topic Title: In Situ Inspection of Additive Manufactured Metallic Parts Using Laser Ultrasonics Proposal No.: N15A-008-0134 Firm: Intelligent Optical Systems, Inc. 2520 W. 237th Street Torrance, California 90505-5217 Contact: Marvin Klein Phone: (424) 263-6361 Web Site: http://www.intopsys.com Abstract: Additive manufacturing (AM) is a very promising technique for rapid, low-cost production of aircraft parts directly from a CAD file. AM is especially appealing for complex parts that would be costly or impossible to fabricate by machining or casting. At the current time there are no reliable, cost-effective techniques to qualify the finished parts. Several government studies have noted this gap and urged increased efforts to develop improved techniques for part qualification. In this project we will demonstrate the feasibility of applying laser ultrasonic testing to evaluate each deposited layer in real time during the build process. This in-line inspection has the benefit of part qualification layer-by-layer, ensuring finished parts that require no further testing. In Phase I we will team with Penn State Applied Research Laboratory, which will supply samples with well characterized defects and give general technical guidance. We will then optimize the beam configuration for the best sensitivity to these defects, and also develop signal processing algorithms to enhance the defect detection threshold and collect size information. In Phase II a prototype in-line inspection system will be developed and tested on a production machine. Benefits: Additive manufacturing is a valuable technique for producing parts that are difficult and expensive to produce by machining or forging. The engine industry for military and commercial aircraft (as well as spacecraft) is adopting additive manufacturing for complicated parts that would be difficult or even impossible to produce by other techniques. Key high-value components such as injection nozzles are found multiple times in a turbine engine. The use of AM will reduce engine weight and cost. Other industries adopting AM include makers of automotive, medical/dental, and consumer products. For DoD as well as other government and commercial applications, the introduction of in-line, real-time laser ultrasonic testing to characterize 3D-printed parts supports Executive Order 13329, "Encouraging Innovation in Manufacturing." Return