Technology Title
GRIT Solution for Corrosion Inspection
Tech Focus Area
Surface Preparation and Corrosion Control
Abstract
Problem Statement:
The DoD faces rising sustainment challenges from aging aircraft, shrinking budgets, and reduced manpower. Hidden corrosion beneath coatings compromises airworthiness, increases downtime, drives up maintenance costs, and shortens airframe life. Traditional inspection methods—visual, dye penetrant, eddy current, and ultrasonic—are labor-intensive, inconsistent, and often require hazardous coating removal (e.g., hexavalent chromium), posing health risks and environmental burdens. These inefficiencies strain resources and reduce readiness. A new approach to corrosion detection, reporting, and tracking is essential.
Description of the Innovative Solution:
The Grey Gecko Real-Time Inspection Tool (GRIT) 125v2.5 is a rugged, handheld, battery-powered NDI system using patented spread-spectrum infrared technology. GRIT penetrates coatings over 20 mils thick, detecting corrosion, cracks, and deformities in aluminum, steel, titanium, and composites with real-time, high-resolution imaging. Unlike legacy methods, GRIT requires no material removal, minimal setup, integrates easily into existing workflows, and needs only one hour of training. Its scalable, cost-effective design modernizes corrosion control, enhancing safety and efficiency across aircraft platforms.
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Benefits to the DoD:
GRIT delivers measurable gains. At the U.S. Coast Guard Aviation Logistics Center (ALC), it cut HC-144 wing joint inspection times by 80%—from 30 to 6 hours—saving $240,000 and 120 labor hours across five depot cycles in 2024, while eliminating hexavalent chromium exposure. On the C-27J, GRIT found spar cap cracks missed by prior NDI, avoiding $1.2M in repair costs and ensuring airworthiness. The USAF Corrosion Office is applying GRIT on C-130s, and Lockheed Martin is evaluating it for F-35 and H-60 aircraft, targeting corrosion on wing skins, fuselage joints, and rotor assemblies. GRIT’s proven effectiveness extends aircraft life, reduces environmental risk, and supports readiness under fiscal constraints.
Innovation Challenges:
Cultural resistance remains: some managers and maintainers hesitate to uncover previously undetected corrosion. GRIT addresses this with intuitive controls and real-time data. At ALC, it revealed moderate corrosion on HC-144 wing joints, prompting timely repairs and building operational trust through actionable insight.
Technical Maturity/Demonstration Results:
With over 32,000 inspection hours and TRL 9 maturity since its 2019 AFWERX Flightline of the Future award, GRIT reflects extensive DoD and OEM input. At ALC, it confirmed OEM bulletin compliance and detected critical wing-to-fuselage fastener corrosion missed by visual checks, preventing mission failure. During 2023–2024 demos at NAS Jacksonville, GRIT proved highly effective on the P-8 Poseidon. It has also shown strong performance on HC-144, C-27J, F-35, C-130, H-60, F/A-18, F-16, F-15, and T-38/F-5, with limited results on the F-22. GRIT is ready for fleetwide deployment.
