N101-011 TITLE: Hand-Held Nondestructive Inspection (NDI) Scanner for Composite Missile Systems

TECHNOLOGY AREAS: Materials/Processes, Weapons

ACQUISITION PROGRAM: PMA-259, Air-to-air Missile Systems; ACAT I

OBJECTIVE: Develop a hand-held non-destructive inspection (NDI) device that can scan complex contoured composite missile structures, e.g. fiber-reinforced plastic (FRP) tubes and FRP sandwich structures.

DESCRIPTION: Composite materials are the future structural material for missile systems as well as complex contoured aero structures. These materials provide higher strength and less weight than traditional metal cases. Composite materials are sensitive to impact damage, frequently as a result of handling accidents. If composites are to be truly viable in the Navy, there must be a method for quickly and nondestructively analyzing an asset after such an accident. Currently methods for nondestructive inspection of composite materials are limited to flat-plate or nearly flat-plate geometries. Missiles do not fit into this limitation due to their small diameter, typically between 2 and 25 inches.

The hand-held device will have to detect defects as small as 0.100 inches diameter or 0.050 inch-wide cracks in both curved and flat surfaces. The device will need to detect delaminations, kissing unbonds, broken fibers, and other defects. It must be portable to allow a sailor to scan a part while stored on a ship at sea. It must have a real-time display with a scale representation of the defect. Energy from the scan cannot interfere with or excite solid rocket propellant or affect sensitive electronics. Only the exterior of missiles will be accessible to the scanner; therefore, it must be able to see through fiberglass, graphite, and aramid reinforcements. Matrix materials may include epoxies, cyanate esters, polyimides, and bismaleimides. Some portions of missiles may be constructed of sandwich panels with aluminum or aramid honeycomb cores. There will also be a paint coating on the exterior of the composite parts. The device must be capable of scanning through the entire thickness of the case, which can vary from 0.060 inches to 0.750 inches. An additional capability would be to detect delaminations in the rocket motor sections between the case to insulation, insulation to liner, and liner to propellant.

PHASE I: Conceptualize and design an innovative nondestructive method for inspecting small-diameter composite structures for the defects listed. Demonstrate technical feasibility.

PHASE II: Develop, demonstrate, and validate a prototype hand-held device capable of detecting the aforementioned defects. Establish performance parameters via experiments and prototype fabrication. Complete component design, fabrication, and laboratory characterization.

PHASE III: Transition the NDI unit to a naval weapon system such as the Advanced Medium Range Air-to-Air Missile.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Hand-held NDI units will make for quicker and easier inspection of many composite products that are currently commercially produced. Wind energy, automobiles, and commercial aviation are all increasingly using composites and stand to gain from this technology. The device could be used for quality control purposes during manufacturing.

REFERENCES:
1. MIL-HDBK-17-3F, Department of Defense Handbook, Composite Materials Handbook, Volume 3. 17 June, 2002

2. Kobayashi, M., Jen, C., L�evesque, D., Flexible Ultrasonic Transducers. IEEE Transactions on Ultrasonics, Ferroelectrics, and Frequency Control, 53 (8), 1478-1486, 2006

KEYWORDS: Nondestructive Inspections; Composite; Delaminations; Rocket Motors; Portable; Scanner

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