Search NASA⌕ Search

SEARCH · Search NASA

Results for “Qualification & Certification”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2026

Computational Materials for Qualification and Certification (CM4QC) Strategy Document: Maturation of Computational Materials Methods for Aviation-Focused Qualification and Certification of Metal Additive Manufacturing (as an Example of Process-Intensive Materials)

Although considerable scientific and technological advances have been made in recent years in additive manufacturing (AM) processes, these advances have not translated into significant market penetration of AM parts within the aviation industry. It is broadly acknowledged that using traditional qualification and certification (Q&C) approaches for AM components is one of the most significant barriers to broader adoption of AM, resulting in high costs, long product development and certification timelines, and complex design iterations during the product development cycle. A new approach is urgently needed. This document lays out a vision for a new Q&C paradigm with increased use of computational materials (CM) methods aimed at decreasing the time and cost of Q&C of process-intensive material (PIM) approaches in the aviation industry, with AM as the immediate use case. This vision was developed with substantial input from industry, regulatory agencies, government research organizations, and academia.

Edward H Glaessgen↗
NASA NTRSDate not supplied

NASA's Certification and Qualification Challenges for Additively Manufactured Hardware: What Is Next?

In 2021, NASA released NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems” to create qualification and certification strategies for mature metallic and non-metallic AM materials and technologies. While these standards have had an immediate impact on the additive manufacturing (AM) industry, there remain many challenges that have yet to be overcome. NASA and its partners in academia and industry are working together to proactively address these issues. One of the most critical needs is a Probabilistic Damage Tolerance Assessment (PDTA) approach, which includes the development of computational modeling, understanding the “effect of defects”, and the implementation of in-situ process monitoring and inspection techniques.

Will Tilson↗
NASA NTRSDate not supplied

Towards Qualification and Certification of Laser Powder Bed Fusion Ti-6Al-4V with In-Situ Process Monitoring and Automated Defect Detection

Qualification and certification of laser powder bed fusion (LPBF) parts are two challenges that must be answered to ensure suitability for critical applications. In-situ monitoring using high frame rate thermal and conventional optical imaging sensors is applied to the LPBF build process. Currently, the large volume of data from such sensors becomes untenable for manual inspection in production environments. This presentation serves to address this in-situ monitoring deficiency in two ways. First, a framework for managing data streams from LPBF process monitoring sensors is described. Second, two candidate image analysis techniques are presented: one is a set of heuristics that are easily interpretable, and the other is an uninterpretable convolutional neural network. These strategies are compared in terms of performance, computational expense, and speed. These methodologies represent platforms for connecting processing conditions to process modeling efforts aligned with the qualification and certification mission for LPBF Ti-6Al-4V components.

Qualification↗
NASA NTRSDate not supplied

Computational Materials for Qualification and Certification of Process-Intensive Metallic Materials (CM4QC)

NASA and the FAA established the Computational Materials (CM) for Qualification and Certification (Q&C) steering group comprised of representatives from industry, government regulatory and research organizations, and academia with the following goals: - Inform the research and development investments made by U.S. industry and the U.S. government toward maturation of CM-based approaches for Qualification and Certification (Q&C) of process intensive metallic materials (PIM) including additive manufacturing. - Identify key considerations and enablers required to increase airworthiness / certifying authorities’ acceptance of CM methods use for Q&C of structural or flight-critical parts produced with PIM technologies. - Identify key CM technology gaps and maturation paths (in the context of Q&C applications). - Increase dialogue among stakeholder organizations. This presentation will summarize the technology and regulatory considerations that motivate this national effort, discuss progress and provide a summary and status of a multi-year roadmap that is being developed to guide technology development in this important area.

Computational Materials↗
DOE OSTI2026

Model-based, in-situ, non-destructive qualification and certification of parts made by autonomous additive manufacturing

To address the significant productivity challenges associated with the qualification and certification (Q&C) tasks of additively manufactured (AM) parts, which have traditionally relied on rigorous post‐build inspection and testing, we propose an integrated framework that combines model‐based qualification and certification (MBQ&C) with autonomous additive manufacturing (AAM). MBQ&C employs high‐fidelity predictive models, developed within the Integrated Computational Materials Engineering (ICME) paradigm, to simulate process–structure–property–performance relationships for assessing a part’s fitness for use. Since predictive models are commonly machine learning (ML)-based or reduced-order surrogates of validated physics models, they run efficiently, enabling timely inference. In parallel, the self-driving AAM utilises ML-based adaptive, closed‐loop control strategies to avoid, mitigate, or repair defects and anomalies during fabrication, thereby increasing the likelihood of producing acceptable parts. A key feature of the combined AAM-MBQ&C framework is that predictive models explicitly incorporate defects or anomalies that persist after the build, using instance-specific data captured via in-situ sensing. This customisation enables a build‐specific assessment of fitness for use, rather than relying on nominal or generic parameters. Such individualised evaluation provides a robust basis for Q&C-related acceptance decisions relating to each build. Additionally, the rapid solution capabilities of ML or reduced-order models enable the determination of a part’s suitability for service shortly after build completion. As the framework matures, it has the potential to substantially reduce reliance on conventional point‐design approaches—such as time‐consuming post‐build computed tomography scanning and costly destructive testing. Thus, the AAM-MBQ&C framework represents a transformative, scalable strategy for quality assurance of AM components, as parts produced within a stable, validated, and certified envelope can be certified with reduced testing. Key benefits include: (1) significant gains in Q&C productivity through efficient, model-centric assessment; (2) performance-based classification of defects into critical and non-critical categories; (3) the ability to predict potential deviations in the performance of parts affected by real-time, adaptive process control interventions relative to those produced under a certified process, and (4) the enabling of virtual Q&C for service environments that are difficult, hazardous, or impractical to access or reproduce experimentally. Collectively, these capabilities strengthen the business case for AM, particularly for high‐consequence and mission‐critical applications. Finally, although this work focuses on powder-based AM, the proposed techniques could be extended to AM processes employing alternative feedstock forms.

Gunasegaram, Dayalan↗
NASA NTRS1994

Role of Wind Tunnels and Computer Codes in the Certification and Qualification of Rotorcraft for Flight in Forecast Icing

The cost and time to certify or qualify a rotorcraft for flight in forecast icing has been a major impediment to the development of ice protection systems for helicopter rotors. Development and flight test programs for those aircraft that have achieved certification or qualification for flight in icing conditions have taken many years, and the costs have been very high. NASA, Sikorsky, and others have been conducting research into alternative means for providing information for the development of ice protection systems, and subsequent flight testing to substantiate the air-worthiness of a rotor ice protection system. Model rotor icing tests conducted in 1989 and 1993 have provided a data base for correlation of codes, and for the validation of wind tunnel icing test techniques. This paper summarizes this research, showing test and correlation trends as functions of cloud liquid water content, rotor lift, flight speed, and ambient temperature. Molds were made of several of the ice formations on the rotor blades. These molds were used to form simulated ice on the rotor blades, and the blades were then tested in a wind tunnel to determine flight performance characteristics. These simulated-ice rotor performance tests are discussed in the paper. The levels of correlation achieved and the role of these tools (codes and wind tunnel tests) in flight test planning, testing, and extension of flight data to the limits of the icing envelope are discussed. The potential application of simulated ice, the NASA LEWICE computer, the Sikorsky Generalized Rotor Performance aerodynamic computer code, and NASA Icing Research Tunnel rotor tests in a rotorcraft certification or qualification program are also discussed. The correlation of these computer codes with tunnel test data is presented, and a procedure or process to use these methods as part of a certification or qualification program is introduced.

Flemming, Robert J.↗
NASA NTRS1990

Space shuttle redesigned solid rocket motor Certificate of Qualification (COQ) data report

The Space Shuttle Redesigned Solid Rocket Motor (RSRM) Certification Program provides confidence that the RSRM and its components/subsystems meet or exceed Mission Oriented Requirements when manufactured per design requirements and specified/approved processes. Certification is based on documented results of tests, analyses, inspections, similarity, and demonstrations. Evidencing information is provided to certify that each RSRM component/subsystem satisfies design, mission related requirements and objectives.

Duersch, Fred, Jr.↗
NASA NTRSDate not supplied

Powder Bed Fusion Laser Beam Metals Additive Manufacturing: Process Monitoring Approaches for Qualification and Certification

The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of powder bed fusion laser beam metal (PBF-LB/M) additively manufactured (AM) parts. Precise monitoring of the PBF-LB/M AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps; the physical interpretation and classification of sensor signals; managing very large datasets; and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power and position throughout a complex PBF-LB/M AM build will be described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection, x-ray computed tomography (XCT). Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality. The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. This presentation will describe an additive manufacturing model-based process metric (AM-PM) computational method that is a fully parallel reduced order modeling approach developed to evaluate the evolution of AM processes. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology of the approach will be described and mapped to the porosity observed from XCT for a complex PBF-LB/M build. Such comparative results develop understanding of how the sequential process actions can affect the PBF-LB/M AM build quality and microstructure variability.

Laser Powder Bed Fusion↗
NASA NTRSDate not supplied

Additive Manufactured Hardware Qualification and Certification at NASA

Additive Manufacturing (AM) is certainly changing the space industry and providing new opportunities to travel to low earth orbit and explore our universe New design opportunities –not previously possible –for new high performance metal alloys, light-weighting, managing thermal, structural, and dynamic loads are being enabled by AM. Additively manufactured parts are already being inserted for complext system for NASA programs in critical applications –“ready to fly” Human exploration of space, especially deep space, requires extreme reliability Qualification of AM design/parts/process and Flight Certification

Alison Park↗