X-Wave Innovations, Inc. — Department of Energy SBIR Phase I: 04b

Description

Radiographic techniques are widely used in non-destructive evaluation (NDE) applications to perform inspections and detect flaws and cracks in component materials. While popular, such techniques pose operational safety risks as well as security risks due to the use of radioisotopic materials. Therefore, the DOE has a goal of reducing dependence on commercial and industrial radioactive materials for nuclear nonproliferation. The DOE and the Office of Proliferation Detection is therefore interested in advanced technology solutions to replace inspection techniques that use radiological sources. The developed technology must adopt non-radioisotopic alternative techniques to perform inspections in a reliable, cost-effective and safe manner. To address this critical need, X-wave Innovations, Inc., teaming up with TechOpp Consulting, Inc., proposes an advanced full matrix capture ultrasonic imaging and inspection suite using ultrasonic phased array (UPA) technology, accompanied by software tools to analyze and interpret acquired ultrasonic imaging data. The key innovations in this proposal include the use of an array of ultrasonic sensors to perform inspections, in the implementation of advanced inspection techniques to enable detection of all manner of material defects, and in the development of analysis and interpretation algorithms to create an uncomplicated inspection suite that is easy to operate and get results from. UPA systems combine several ultrasonic transducers in a single probe, and each constituent transducer can be setup to act as ultrasonic transmitter and receiver independently or in synchrony with other transducers to query a three-dimensional material region. The UPA will be used for full matrix capture (FMC), where each transducer is activated in sequence while every transducer acts as receiver. Through this arrangement, multiple sets of responses are acquired by each sensor corresponding to the slightly different paths traveled by the sound waves. The acquired responses will be time shifted, weighted and combined using the Total Focusing Method (TFM) to artificially ‘focus’ the ultrasonic waves successively at each point within the material, and use the resultant response to estimate the presence and extent of flaws at each point. During the Phase I program, we will build a prototype sensor hardware and demonstrate the feasibility of the proposed approach. We will implement the full matrix capture data acquisition technique for inspecting test specimens. We will develop algorithms to analyze and combine the numerous ultrasonic signals acquired in different configurations. This process is meant to superpose the ultrasonic signals to simulate their focusing in different parts of the test specimen, thus allowing accurate inspection of all regions. We will also develop tools to present analysis results.The proposed project has a clear path to transition into commercial applications. The proposed technology replaces radiographic methods and is inherently safe and secure, thus reducing additional operational expenses associated with additional security and safety precautions associated with radio-isotopic techniques. The proposed technology is capable of detecting various different flaws, is reliable and robust in all environs, and easy to setup and operate. The combination of these qualities presents an attractive proposition to prospective customers. We therefore envision that the proposed full matrix capture ultrasonic imaging based inspection system will be widely applicable in different scenarios. XII is in a unique position to promote and introduce this new technology, thanks to our established partnerships with prime contractors and market leaders in the defense community and the commercial sector. XII will initiate commercialization efforts by working closely with our partners, and we will leverage our connections and actively engage with market leaders to push through the technology transition and commercialization.