Over the life time of the Space Shuttle program, metal parts used for the Reusable Solid Rocket Motors (RSRMs) have been nondestructively inspected for cracks and surface breaking discontinuities using magnetic particle (steel) and penetrant methods. Although these inspections adequately screened for critical sized cracks in most regions of the hardware, it became apparent after detection of several sub-critical flaws that the processes were very dependent on operator attentiveness and training. Throughout the 1990s, eddy current inspections were added to areas that had either limited visual access or were more fracture critical. In the late 1990s, a project was initiated to upgrade NDE inspections with the overall objective of improving inspection reliability and control. An automated eddy current inspection system was installed in 2001. Figure 1 shows one of the inspection bays with the robotic axis of the system highlighted. The system was programmed to inspect the various case, nozzle, and igniter metal components that make up an RSRM, both steel and aluminum. For the past few years, the automated inspection system has been a part of the baseline inspection process for steel components. Although the majority of the RSRM metal part inventory is free of detectable surface flaws, a few small, sub-critical manufacturing defects have been detected with the automated system. This paper will summarize the benefits that have been realized with the current automated eddy current system, as well as the flaws that have been detected.

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