Advanced Field-Use Instrument for Nondestructive Fatigue Damage Assessment of Aging Aerospace Systems

Period of Performance: 05/13/1999 - 05/13/2001


Phase 2 SBIR

Recipient Firm

Hypernex, Inc.
3006 Research Dr., Ste. A1
State College, PA 16801
Principal Investigator


Phase I results prove the capacity of an XRD multigrain peak broadening technique to measure and map fatigue damage throughout fatigue life of metal alloys. During Phase II, we will develop the technology for a full-scale instrument to determine the fatigue damage and remaining service life for aging metal structures. The technology will be based on state-of-the-art capillary x-ray optics, and an advanced fiber-optic/CCD x-ray detector recently developed at ATMI. The life span estimation will use the measured micro-defect density to compare to a parametric map based on the alloy composition, residual stress and loading conditions. The map will be based on the structural change of diffraction spots from individual grains during the course of fatigue life. The fatigue damage measurement methodology will be determined and validated by testing aluminum and titanium alloys with a variety of cold-working levels and interrupted cyclic loading experiments. Finally, a Fatigue Damage Assessment instrument will be built and delivered upon completion of the program. A successful Phase II program will result in a commercial turnkey system being introduced into the market almost immediately following the Phase II program.