Nondestructive Evaluation of 3D Printed Composites using Terahertz Waves
Abstract
Research: Recent advances in nondestructive evaluation (NDE) and additive manufacturing (AM) of polymer matrix composite materials (PMCs) are stimulating research and development activities throughout the United States with emphasis on the next generation of defense systems. In general, PMCs are a strategic class of materials, offering high performance (e.g., strength, stiffness, and toughness) with relatively lower weight than their conventional counterparts. The performance-to-weight ratio is associated with longer deployment times while substantially reducing fuel consumption, i.e., significant environmental and economic benefits. However, evaluating and replacing PMCs parts during a mission is faced with several technological and scientific challenges, namely the lack of a viable additive manufacturing approach for largescale PMCs parts and the absence of a practical nondestructive evaluation approach for onboard fabrication and characterization. Therefore, this project aims to develop a novel approach to combat these challenges, allowing the additive manufacturing of largescale PMCs parts and structures while concurrently performing an in-operando terahertz-based nondestructive evaluation anywhere. The proposed approach is anchored in the recent advances in robotic 3D printers of continuous fiber reinforced PMCs and terahertz-based imaging and tomography. On the one hand, robotic AM systems can produce meter-scale PMCs components using a wide variety of materials, allowing the research community to leap forward from coupon characterization of AM-produced samples to assessment of the structural performance of these materials. On the other hand, terahertz-based NDEs are nonionizing, penetrative, and noninvasive, making them a safe and practical alternative to X-ray NDEs. The approach is then to first focus on the concurrent demonstrations of the technological feasibility of the terahertz-based nondestructive method for detecting defects of PMCs structures and the fabrication of meter-scale AM-produced continuous fiber PMCs parts using robotic 3D printers. After that, the terahertz and 3D robotic subsystems will be integrated to introduce the first real-time in-operando nondestructive evaluation and manufacturing system for polymer matrix composites. While, these proposed activities resemble a paradigm shift in NDE and AM of continuous fiber PMCs, it also provides unprecedented opportunities to train the next generation of engineers and scientists from underrepresented minorities on technologies of great importance to the United States Department of Defense, e.g., next Navy. Therefore, we will engage women and underrepresented minority students from different academic levels in the scientific research enterprise. Research-related Education: The proposed research is essential to enhance SDSUÕs research infrastructure, allowing the research team to enact its vision of ÒAdvancing Mechanics and Broadening ParticipationÓ on a larger scale. Notably, the focus on scientific innovations and the meaningful engagement of underrepresented students in research is entirely congruent with the objective of this funding mechanism. This, in turn, will provide research opportunities to students from different academic levels, from high school to postgraduate, consistent with SDSUÕs culture and mission of providing: Òwell-balanced, high-quality education.Ó Specifically, unrepresentative and underserved students will have access to our Young Engineer Experience (for high schoolers) and Junior Research Experience (for undergraduates, including veterans and military-connected). Finally, collaborative research centered on the proposed project will prepare the students to be the next leaders in composite materials, additive manufacturing, and nondestructive evaluation, designing all future U.S. navies.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- May 24, 2023
- Source ID
- W911NF2310150
Entities
People
- George Youssef
Organizations
- Army Contracting Command
- Office of the Secretary of Defense
- Salk Institute for Biological Studies