Non-invasive quantitative multi-layer evaluation method and resulting multi-layer component

Abstract

An automation system is provided. The system includes a manipulator coupled to an opening forming device configured to form an opening having a predefined geometry partially into the multilayer component at a selected location on a surface of the multilayer component, where the multilayer component includes a plurality of layers of material, a plurality of material layers including at least a substrate and a bond coat, and wherein the opening exposes each of the plurality of material layers; and an imaging device configured to create an image of the exposed plurality of material layers in the opening; and a processor configured to calculate at least a thickness of the bond coat of the exposed plurality of material layers from the image and based on a predefined geometry of the opening. Methods of using the system to analyze the layer thickness of and repair a multi-layer component are also provided.

Description

[0001] Cross - reference to related applications

[0002] This application is a partial continuation patent application of U.S. Patent Application No. 16 / 701,243, filed on December 3, 2019, which claims the benefit of European Patent Application No. 18210779.7, filed on December 6, 2018. The entire disclosure of the European patent application is incorporated herein by reference in its entirety. Background of the Invention

[0003] The present disclosure generally relates to non - destructive material testing and, more particularly, to methods for analyzing quantitative data regarding layers of a multi - layer component and the resulting multi - layer component.

[0004] Quantitative studies and quality checks of material properties are generally required to determine, for example, the thickness of a coated layer, depletion levels, etc. Such evaluations are typically used for process qualification, regular production monitoring, determining the remaining service life of a multi - layer component, or as an initial assessment for determining the scope of repair of a multi - layer component. To perform these evaluations, cuts are made in commercial components. As a result, the components are destroyed (scrapped) and need to be replaced with new parts. Limited non - destructive testing can be used to evaluate, for example, interface delamination or layer thickness using thermography for ceramic layers on a metal substrate. However, these methods lack the ability to provide quantitative data regarding service - life - related properties and specifically the loss of bond coats. Additionally, such evaluations cannot be performed in - field (neither in - situ nor on disassembled parts). Summary of the Invention

[0005] A first aspect of the present disclosure provides a method for analyzing the layer thickness of a multi - layer component, the method comprising: forming an opening having a predefined geometry that partially enters the multi - layer component at a selected location on a surface of the multi - layer component, wherein the multi - layer component comprises a plurality of material layers, the plurality of material layers comprising a substrate and a bond coat, and the opening exposes each of the plurality of material layers including the substrate; creating an image of the exposed plurality of material layers in the opening using a digital microscope; and calculating at least the thickness of the bond coat of the exposed plurality of material layers based on the image and based on the predefined geometry of the opening.

[0006] A second aspect of the present disclosure provides a multi-layer component, the multi-layer component comprising: a substrate; an adhesive coating on the substrate; a thermal barrier coating (TBC) layer on the adhesive coating, the TBC layer having a first outer surface, the first outer surface having signs of exposure to a hot gas path environment; and a fill opening located in the substrate, the adhesive coating, and the TBC layer, the fill opening comprising: a substrate repair filler that fills the fill opening located in the substrate; an adhesive coating repair filler that fills the fill opening located in the adhesive coating; and a thermal barrier coating (TBC) plug that fills the fill opening located in the TBC layer, the TBC plug having a second outer surface that does not have signs of exposure to a hot gas path environment or has fewer signs of exposure to a hot gas path environment.

[0007] A third aspect of the present invention includes a method for analyzing the layer thickness of a multi-layer component, the method comprising: drilling to form an opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component comprises a plurality of material layers, the plurality of material layers comprising a substrate and an adhesive coating on the substrate, and wherein the opening exposes each of the plurality of material layers; increasing the contrast uniquely in the plurality of exposed material layers in the opening by polishing and etching the plurality of exposed material layers; creating an image of the plurality of exposed material layers in the opening using a digital microscope; calculating at least the thickness of the adhesive coating based on the image and based on the predefined geometry of the opening; and repairing the opening so that the multi-layer component can be used for its intended purpose.

[0008] A fourth aspect of the present invention includes an automated system for analyzing the layer thickness of a multi-layer component, the automated system comprising: a manipulator coupled to: an opening forming device configured to form an opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component comprises a plurality of material layers, the plurality of material layers at least comprising a substrate and an adhesive coating, and wherein the opening exposes each of the plurality of material layers; an imaging device configured to create an image of the plurality of exposed material layers in the opening; and a processor configured to calculate at least the thickness of the adhesive coating of the plurality of exposed material layers based on the image and based on the predefined geometry of the opening.

[0009] The fifth aspect of the present disclosure includes a method for analyzing the layer thickness of a multi-layer component using an automated system, the automated system including a manipulator and a processor, the method including: receiving a multi-layer component at the manipulator of the automated system; forming an opening using an opening forming device coupled to the manipulator, the opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component includes a plurality of material layers, the plurality of material layers including at least a substrate and a bond coat, and wherein the opening exposes each of the plurality of material layers; creating an image of the exposed plurality of material layers in the opening using an imaging device coupled to the manipulator; and calculating, by the processor of the automated system, at least the thickness of the bond coat of the exposed plurality of material layers based on the image and based on the predefined geometry of the opening.

[0010] The sixth aspect of the present disclosure includes a method for repairing a multi-layer component using an automated system, the automated system including a manipulator and a processor, the method including: receiving a multi-layer component at the manipulator of the automated system; forming an opening using an opening forming device coupled to the manipulator, the opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component includes a plurality of material layers, the plurality of material layers including at least a substrate and a bond coat, and wherein the opening exposes each of the plurality of material layers; creating an image of the exposed plurality of material layers in the opening using an imaging device coupled to the manipulator; calculating, by the processor of the automated system, at least the thickness of the bond coat of the exposed plurality of material layers based on the image and based on the predefined geometry of the opening; and repairing the opening using a repair device coupled to the manipulator of the automated system. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] These and other features of the present disclosure will be more readily understood from the following detailed description of the various aspects of the present disclosure in conjunction with the drawings depicting the various embodiments of the present disclosure, in which:

[0012] Figure 1 A perspective view of an exemplary multi-layer component in the form of a turbine blade is shown.

[0013] Figure 2 A cross-sectional view of an exemplary layer of the multi-layer component is shown.

[0014] Figure 3 A cross-sectional view of forming an opening according to an embodiment of the present disclosure is shown.

[0015] Figure 4 A cross-sectional view of forming an opening according to another embodiment of the present disclosure is shown.

[0016] Figure 5A cross-sectional view is shown that optionally increases the contrast of the layer in the opening according to an embodiment of the present disclosure.

[0017] Figure 6 A cross-sectional view is shown that creates an image of the layer in the opening according to an embodiment of the present disclosure.

[0018] Figure 7 A schematic diagram is shown of an exemplary image of the layer in the opening according to an embodiment of the present disclosure.

[0019] Figure 8 A schematic diagram is shown of the layer of the opening for calculating the layer thickness according to an embodiment of the present disclosure.

[0020] Figure 9 A cross-sectional view is shown of the layer of the repaired multi-layer component according to an embodiment of the present disclosure.

[0021] Figure 10 A cross-sectional view is shown of the layer of the repaired multi-layer component according to another embodiment of the present disclosure.

[0022] Figure 11 A block diagram is shown of an exemplary automation system according to an embodiment of the present disclosure.

[0023] Figure 12 A flowchart is shown of an exemplary automation method according to an embodiment of the present disclosure.

[0024] Figure 13 A flowchart is shown of a second exemplary automation method according to an embodiment of the present disclosure.

[0025] Figure 14 A flowchart is shown of a third exemplary automation method according to an embodiment of the present disclosure.

[0026] It should be noted that the drawings of the present disclosure are not drawn to scale. The drawings are intended to depict only typical aspects of the present disclosure and should not therefore be considered as limiting the scope of the present disclosure. In the drawings, like numbers represent like elements between the drawings. Detailed Description

[0027] As an initial matter, in order to clearly describe the present disclosure, it will be necessary to select certain terms when referring to and describing the relevant parts of a multi-layer component. In doing so, where possible, common industry terms will be used and adopted in a manner consistent with their accepted meanings. Unless otherwise noted, such terms should be given a broad interpretation consistent with the context of the present application and the scope of the appended claims. Those of ordinary skill in the art will appreciate that several different or overlapping terms may often be used to refer to a particular component. An object that may be described herein as a single part may include multiple components and in another context may be referred to as being composed of multiple components. Alternatively, an object that may be described herein as including multiple components may elsewhere be referred to as a single part.

[0028] In cases where an element or layer is referred to as "open", "engaged", "disengaged", "connected to", or "coupled to" another element or layer, it may be directly thereon, engaged to, connected to, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as "directly on another element or layer", "directly engaged to another element or layer", "directly connected to another element or layer", or "directly coupled to another element or layer", intervening elements or layers may not be present. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between", "adjacent" versus "directly adjacent", etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0029] Embodiments of the present invention provide a method for analyzing quantitative data (such as layer thickness) of a multi-layer component. The method utilizes the minimally invasive impact on the multi-layer component to obtain the required quantitative data. Specifically, an opening is formed in the multi-layer component, which can be fully restored using available (local) repair procedures if necessary, while enabling the reuse of commercial multi-layer components. Additionally, component evaluation can be performed during component manufacturing and at the point of use. On-site repair solutions can be used to repair the component on-site.

[0030] Figure 1 A perspective view of an exemplary multi-layer component 100 in the form of a turbine blade is shown. The teachings of the present disclosure can be applied to any multi-layer component made using any method of forming layers (e.g., welding, brazing, thermal spraying, etc.). As Figure 2As shown in the cross-sectional view, the multi-layer component 100 may include a plurality of material layers. In the example shown, one or more protective layers 106 may be located on the substrate 104. The substrate 104 may include any metal or metal alloy used as a metal substrate, or a ceramic such as a ceramic matrix composite. For the purpose of a turbine blade, the substrate 104 may include, for example, a superalloy, which may refer to an alloy having many excellent physical properties compared to conventional alloys, such as but not limited to: high mechanical strength, high resistance to thermal creep deformation, etc. Superalloys include but are not limited to: Rene 108, CM247, Haynes alloys, Incalloy, MP98T, TMS alloys, CMSX single crystal alloys, N5, GTD 444, MarM 247, and IN 738. Alternatively, the substrate 104 may include a variety of other metals or metal alloys. "γ′" (gamma prime) is the main strengthening phase of nickel-based alloys. Exemplary high γ′ superalloys include but are not limited to: Rene 108, N5, GTD 444, MarM 247, and IN 738. In one embodiment, the bond coat 110 may include a γ-γ′ structure (e.g., the γ′ phase [Ni3(Al,Ti)] phase in a γ matrix γ-Ni(Co,Cr)), and in another embodiment, the substrate 104 may include a γ-β structure, such as the β-NiAl phase in a γ matrix γ-Ni(Co,Cr). In terms of ceramics, the substrate 104 may include any presently known or later developed ceramic configured to perform in a hot gas path environment.

[0031] The protective layer 106 may include any presently known or later developed protective layer for, for example, protecting the substrate 104 from a hot corrosive environment. In one embodiment, the protective layer 106 may include at least one of a bond coat 110 (also referred to as an overlay coat if used alone) and a top coat 112 located on the bond coat (note that "top coat" does not necessarily mean that layer 112 is the outermost coat). The bond coat 110 may include any presently known or later developed bond coat material, such as but not limited to: nickel or platinum aluminide compounds, nickel-chromium-aluminum-yttrium (NiCrAlY), or nickel-cobalt-chromium-aluminum-yttrium (NiCoCrAlY). The bond coat 110 may include a γ-γ' structure (e.g., the γ′ phase [Ni3(Al,Ti)] phase in a γ matrix γ-Ni(Co,Cr)). In one embodiment, the bond coat 110 may include a metal (M) having a chromium-aluminum-yttrium alloy (MCrAlY), such as those commercially available from Amdry under the designations 4522A and 4522C. The bond coat 110 may be coated using, for example, high velocity oxygen fuel (HVOF) coating, low pressure plasma spraying (LPPS), or air plasma spraying (APS).

[0032] The thermal barrier coating (TBC) layer 114 may be disposed on the bond coat 110. The material of the TBC layer 114 may include, for example, yttria-stabilized zirconia (YSZ), mullite, and alumina.

[0033] During operation, as Figure 3 shown, elements may diffuse from the bond coat 110 to form a depletion layer 118, and some of the elements may eventually oxidize to form a thermally grown oxide layer 116 (hereinafter referred to as "oxide layer 116"). Depending on the composition of the substrate 104 and how the bond coat 110 is formed, the oxide layer 116 may or may not be formed by the diffusion of aluminum (e.g., the γ'-phase [Ni3(Al,Ti)] phase in the γ-matrix γ-Ni(Co,Cr)) from the bond coat 110 during operation.

[0034] Three exemplary arrangements of the substrate 104 and the bond coat 110 that are advantageous in the embodiments of the present disclosure include the following. A) A substrate 104 having an MCrAlY bond coat 110 with a γ-γ' structure coated by HVOF or LPPS, which exhibits depletion in the bond coat 110 to form a depletion layer 118, which can be identified using the teachings of the present disclosure. Here, for example, aluminum diffuses and oxidizes to form the oxide layer 116. The embodiments of the present disclosure allow the measurement of the depletion of the bond coat 110. B) A substrate 104 having an MCrAlY bond coat 110 with a γ-β structure coated by APS. Here, as Figure 4 shown, no depletion occurs, and only the thickness of the bond coat 110 is measured using the embodiments of the present disclosure, i.e., since the deterioration of the bond coat 110 cannot be measured by this method. C) A substrate 104 having an MCrAlY bond coat 110 with a γ-β structure coated by HVOF or LPPS. As Figure 3 shown, due to the operation (as in arrangement A) that can be identified using the teachings of the present disclosure, i.e., aluminum diffuses and oxidizes to form the oxide layer 116, the latter arrangement exhibits a depletion layer 118 in the bond coat 110. Although two to three protective layers 106 have been illustrated, it is emphasized that the teachings of the present invention are applicable to any number of layers and various diffusing elements. Materials other than TBC may also be employed.

[0035] Figure 3 and Figure 4 Also shown is the formation of an opening 120 having a predefined geometry that partially enters the multi-layer component 100 at a selected location on the surface of the multi-layer component 100, i.e., a test site opening. Before forming the opening 120, as in Figure 3In most of the cases shown, at least a part of the TBC layer 114 is removed, for example, by shot peening or sandblasting. Only the area necessary for forming the opening 120, for example, by drilling, needs to be removed from the TBC layer 114. That is, it is not necessary to remove all of the TBC layer 114, and only an area slightly larger than the area of the tool used to manufacture the opening 120 needs to be removed. The opening 120 can be formed in various ways to form a predefined geometry in the multi-layer component 100. In one embodiment, as Figure 3 shown, the opening 120 is formed by drilling a tapered hole 122. Other differently shaped holes are also possible. For example, Figure 4 shows an opening 120 formed by calotte grinding to form a spherical segment opening 124. Other material removal tools can also be used, such as milling tools, to form a predefined geometry in the multi-layer component 100. The "predefined geometry" can include points, lines, surfaces, angles, lengths, and any other shape with known dimensions. As will be described, the predefined geometry allows the dimensions obtained from the image of the opening 120 to be used to calculate quantitative data regarding the layers and specifically the bond coat 110, such as but not limited to: layer thickness, depletion level, interdiffusion level, or the presence of a heat affected zone. In Figure 3 an example of an embodiment, the drill bit can have an exact point angle between approximately 130° and 150°, and a diameter of, for example, approximately 2.5 mm to 7 mm. The position of the opening 120 can be selected by the user to, for example, provide a visual assessment of the component (after new manufacture / use) and to define material properties if necessary. More than one opening 120 can be used to test various local regions of the multi-layer component 100. Depending on the component condition, different parameters can be evaluated at different positions without being subject to conventional limitations, that is, if a destructive test is used, a specified cutting plan for the component is required. A mask (not shown) can be used for routine inspections at repeatable positions.

[0036] As Figure 5 shown, for Figure 3 the drilling embodiment, the opening 120 exposes each material layer of the material layers 104, 110 (116, 118, if present) including the substrate 104. That is, at least a certain part of each layer 104, 110 (116, 118, if present) is exposed through the opening 120, for example, the surface, corners, edges, etc. The size of the opening 120 can be based on various factors, such as but not limited to: coating thickness, expected worst-case wall penetration thickness, desired minimum and / or maximum thickness of the opening 120, etc. An appropriate drill bit diameter and angle can be selected based on any of these factors. The substrate 104 should be exposed to a minimum extent and should be exposed in a manner that does not form cracks or other extensive damage therein. The drilling speed and the downward pressure are precisely controlled to achieve the above situation.

[0037] In some cases, it is beneficial to increase the contrast compared to the contrast presented after forming the opening 120. Figure 5 It is also shown to optionally increase the contrast of the plurality of exposed material layers 104, 110, 118 uniquely within the opening 120. In one embodiment, the process may include polishing the plurality of exposed material layers 104, 106. The process may include, for example, polishing using a felt 140 with diamond polishing paste 142. In such a case, increasing the contrast may also optionally include, for example, etching 144 the plurality of exposed material layers 104, 106 after polishing. The etching may include using any currently known or later developed etchant, such as but not limited to: molybdic acid etchant for aluminum-rich phases, or Murakami etchant for chromium-rich phases. Surface contrast can also be enhanced by electrochemical etching. For example, in cases where the bond coat 110 is depleted, such as in arrangements A) and C) described herein, polishing may be beneficial. In this way, embodiments of the present disclosure can obtain the bond coat 110 thickness and the depletion layer 118 thickness, i.e., how much of the bond coat 110 is diffused to form the depletion layer 118 (and oxide layer 116) and how much of the bond coat 110 remains. The depletion layer 118 thickness and the bond coat 110 thickness may be related to the remaining life of the bond coat 110 (i.e., the expected life of the bond coat 110). In other embodiments, it is not necessary to increase the contrast, i.e., polishing or etching is not performed. The latter process can be applied to certain bond coats 110 that are not depleted, for example, any degradation due to internal oxidation, such as arrangement B) described herein.

[0038] Figure 6 It is shown to create an image of the plurality of exposed material layers 104, 106 within the opening 120 using a digital microscope 150 (e.g., a handheld and portable version). The digital microscope 150 can include any currently known or later developed microscope. In one embodiment, the digital microscope 150 can be handheld and portable, so it can be used in the field of use of multi-layer components, such as inside a turbine.

[0039] Figure 7 An example image 152 of the opening 120 and the exposed material layers for the multi-layer component 100 in use is shown. It should be understood that a newly manufactured multi-layer component 100 will only have the bond coat 110 and the substrate 104. The depth or thickness of the bond coat 110 can be calculated based on the image 152 based on the predefined geometry of the opening 120. Figure 8 It is shown from Figure 6Schematic diagram of dimensions derived from the image 152 of the opening 120, such as the transverse diameters of layers d1, d2, and d3 of layers 104, 110, and 118, respectively. The predefined geometry of the opening 120 provides a known angle α of the exposed surfaces of layers 104, 110, and 118. The application of trigonometry gives T1 = ((d2 / 2) - (d1 / 2))tanβ, and T2 = ((d3 / 2) - (d2 / 2))tanβ. The angle β is the angle of the opening 120 relative to the horizontal plane. Thus, the thickness (T1) of the bond coat 110 can be determined. Additionally, when present, the thickness (T2) of the depletion layer 118 can be determined. The thickness (T2) of the depletion layer 118 indicates the amount of depletion of the bond coat 110. That is, the thickness of the depletion layer 118 can be used to determine the remaining life (expected life) of the bond coat 110.

[0040] Based on the calculated thicknesses, the determination of quantitative data can be ascertained, such as but not limited to: the thickness of the bond coat 110, i.e., the complete thickness of the bond coat 110, and the thickness of the depletion layer 118 produced by the diffusion process. For new manufacturing, the thickness of the bond coat 110 can be used to confirm, for example, the quality of the product and as a benchmark for subsequent evaluation based on the bond coat thickness. For used multi-layer components 100, the amount of depletion of the bond coat 110 can be used to predict the remaining expected life, for example, using conventional algorithms or experience-based modeling techniques. For example, for a known bond coat material, if 50% of the bond coat 110 has been used, it can indicate 1200 operating hours remaining under the expected operating conditions of the multi-layer component 100. Additionally, the thickness of the bond coat 110 and / or the thickness of the depletion layer 118 can also be used to determine the expected life of the bond coat 110.

[0041] Compared to conventional destructive material testing, the multi-layer component 100 can be evaluated and, if necessary, repaired. That is, the opening 120 can be repaired, allowing the multi-layer component 100 to be used for its intended purpose, such as an airfoil. The repair process can include any presently known or later developed repair process for the opening 120 in the provided materials. For example, the repair of the substrate 104 and the bond coat 110 can include at least one of laser wire welding or tungsten inert gas (TIG) welding. The repair device can be handheld. Alternatively, the substrate 104 and / or the bond coat 110 can be repaired by a thermal spraying process (e.g., APS, flame spraying, etc.). The repair of the TBC layer 114 can include any thermal spraying process, such as one of APS and flame spraying. Alternatively, the TBC 114 can include a slurry coating process. The oxide layer 116 is not repaired. Figure 9 Shows the repaired opening 120 (for Figure 3 the embodiment of

[0042] As described above, embodiments of the methods described herein may be performed prior to use of the multi-layer component 100 (i.e., after manufacture) to confirm proper manufacture and / or reference layer thickness. Alternatively, embodiments of the present disclosure may be performed at the geographical location where the multi-layer component 100 is used, e.g., a power generation facility in the case of a turbine rotor blade. When the multi-layer component 100 is on-site, it may be removed from its use environment, or it may remain in its use environment, e.g., inside a turbine. If it remains in place, the multi-layer component 100 may be used after repair of the opening 120, e.g., without reinstallation. If on-site, repair of the opening 120 may include use of at least one hand-held device, such as a TIG welder, flame spray, etc.

[0043] Figure 9A cross-sectional view of a used (i.e., no longer in service) multi-layer component 100 after exposure to a method according to an embodiment of the present disclosure is shown. The multi-layer component 100 may include a substrate 104, a bond coat 110 on the substrate 104, and a TBC layer 114 on the bond coat 110. The TBC layer 114 has a first outer surface 170 that, for example, shows signs of exposure to a hot gas path environment according to its use in a gas turbine. That is, the first outer surface 170 may be, for example, dirty, worn, and / or have a different color or shade. Filled openings 172 are located in the substrate 104, the bond coat 110, and (if provided) the TBC layer 114. An oxide layer 116 and / or a depletion layer 118 may be present outside the filled openings 172. The filled openings 172 include a substrate repair filler 164 that includes a material that is the same as or similar to (possibly having better properties) the metal of the substrate 104 that fills the filled opening 120 in the substrate 104 (i.e., in the substrate portion 160 of the opening 172). The multi-layer component 100 also includes a bond coat repair filler 174 that fills the filled opening 172 in the bond coat 110 (i.e., in the bond coat portion 168 of the opening 120). The bond coat repair filler 174 includes a material that is the same as or similar to (possibly having better properties) the bond coat 110. As shown, since the opening 120 in the substrate 104 is very small, the substrate repair filler 164 may be the same material as the bond coat repair filler 174, i.e., the repair fillers 164 and 174 are the same. In this case, the bond coat repair filler 174 extends into the substrate 104. A thermal barrier coating (TBC) plug 176 fills the filled opening 172 in the TBC layer 114, i.e., where the TBC layer 114 has been removed. The TBC plug 176 has a second outer surface 176 that does not show signs of exposure or has fewer signs of exposure than the first outer surface 170 of the TBC layer 114 because the second outer surface has not experienced the operating atmosphere and temperature, or a different manufacturing process has been used to coat the second outer surface, i.e., the second outer surface is newer (possibly having slightly different properties, such as porosity), has less dirt on it, and may have a different color / shade than the TBC layer 114. The TBC plug 176 (shown) or the bond coat repair filler 174 may fill the filled opening 172 located in the oxide layer 116 and / or the depletion layer 118. In Figure 9 an example, the opening 120 has an outer perimeter that includes at least a portion having a tapered shape. It should be understood that in the case of an opening 120 employing an Figure 4 embodiment, the opening 120 will include a perimeter having at least a spherical portion. However, in any case, as Figure 9As shown, the perimeter of the opening 120 is not visible to the naked eye in the outermost layer (e.g., the TBC layer 114 and the TBC plug 176). The final repair process may include, for example, trimming the profile of the outer surfaces 170, 176 of the multi-layer component 100 by grinding or polishing.

[0044] Figure 10 Another embodiment is shown, where the repair includes repairing only the substrate 104 with a substrate repair filler 164 in the filled opening 172 and repairing the bond coat 110 with a bond coat repair filler 174. Here, there is no depletion layer 118, oxide layer 116, and TBC layer 114. Again, since the opening 120 in the substrate 104 is very small, the substrate repair filler 164 can be the same material as the bond coat repair filler 174, i.e., the repair fillers 164 and 174 are the same. The TBC layer 114 is not provided or repaired. The final repair process may include, for example, trimming the profile of the surface 154 of the multi-layer component 100 by grinding or polishing. In Figure 10 which, the presence of the opening 120 is not visible to the naked eye on the surface 154. However, if cut open, the residue of the opening 120 can be observed in the multi-layer component 100.

[0045] Embodiments of the present disclosure provide a quantitative assessment (e.g., thickness, depletion, bonding, heat affected zone, etc.) of multi-layer components (e.g., substrates with coatings, brazing, welding, etc.), which has a minimal destructive impact on commercial components while enabling them to be reused through local material repair when necessary. Thus, the method avoids a comprehensive metallurgical study by cutting / destroying commercial parts and the scrapping of parts for the metallurgical study of multi-layer components. Additionally, the method allows for condition-based repair and can reduce the scope of repair compared to destructive testing techniques. The method can be used in the art during manufacturing or after use.

[0046] Any embodiment of the present disclosure can be performed manually, automatically, or in a combination of manual and automatic. In some embodiments, the method is automated. In some embodiments, the method is automated using any suitable automation techniques known in the art that facilitate the success of the methods described herein. In some embodiments, the method is automated using an automated system.

[0047] Figure 11 A block diagram of an example automated system 200 for analyzing the layer thickness of a multi-layer component part 300 is shown. The automated system 200 can be used according to the methods of the present disclosure, including Figures 12 to 14 the methods shown in

[0048] The automated system 200 includes a processor 202, a controller 204, a power supply 206, a manipulator 208, and an attachment 210.

[0049] The processor 202 can be any suitable processor known in the art that facilitates the success of the systems described herein. The processor 202 is configured to process image processing software. The processor 202 is further configured to calculate at least the thickness of the bonding coating and / or the thickness of the depletion layer of the plurality of exposed material layers based on the image and the predefined geometry of the opening.

[0050] The controller 204 can be any suitable controller known in the art that facilitates the success of the systems described herein. The controller 204 is in electronic communication with the power supply 206, the processor 202, and the manipulator 208, and is configured to control each of them.

[0051] The power supply 206 can be any suitable controller known in the art that facilitates the success of the systems described herein.

[0052] The manipulator 208 can be any suitable manipulator known in the art that facilitates the success of the systems described herein. The manipulator 208 can be in the form of a robotic arm. The manipulator 208 can be mechanically and / or electronically coupled to one or more attachments 212 and / or one or more tools 400. The tool 400 is separate from the automation system 200, and the attachment 210 is detachable from the automation system 200. The manipulator 208 is configured to interact with the multi-layer component part 300, the attachment 210, and the tool 400.

[0053] The attachment 210 can be any suitable attachment known in the art that facilitates the success of the systems described herein. For example, the manipulator can have a drilling device attachment for drilling, a polishing device attachment for polishing and preparation, and an imaging device attachment for imaging.

[0054] Figure 12 A flowchart of an example automated method 500 for analyzing the layer thickness of a multi-layer component part using an automated system including a manipulator and a processor is shown. The method includes receiving 502 the multi-layer component at the manipulator of the automated system; forming 504 an opening using an opening forming device coupled to the manipulator, the opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component includes a plurality of material layers, the plurality of material layers including at least a substrate and a bonding coating, and wherein the opening exposes each of the plurality of material layers; creating 506 an image of the plurality of exposed material layers in the opening using an imaging device coupled to the manipulator; and calculating 508 at least the thickness of the bonding coating of the plurality of exposed material layers based on the image and the predefined geometry of the opening using the processor of the automated system.

[0055] Figure 13A flowchart of an example automated method 600 for repairing a multi-layer component using an automated system including a manipulator and a processor is shown. The method includes receiving 602 a multi-layer component at the manipulator of the automated system; forming 604 an opening using an opening forming device coupled to the manipulator, the opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component includes a plurality of material layers, the plurality of material layers including at least a substrate and a bonding coating, and wherein the opening exposes each of the plurality of material layers; creating 606 an image of the exposed plurality of material layers in the opening using an imaging device coupled to the manipulator; calculating 608 at least the thickness of the bonding coating of the exposed plurality of material layers by the processor of the automated system based on the image and based on the predefined geometry of the opening; and repairing 610 the opening using a repair device coupled to the manipulator of the automated system.

[0056] Figure 14 A flowchart of an example automated method 700 for analyzing the layer thickness of a multi-layer component part is shown. The multi-layer component part is loaded 702 into the automated system. The manipulator drills 704 a hole in the multi-layer component part. The manipulator uses 706 a polishing device to polish and prepare the hole surface. The manipulator uses 708 an imaging device to record an image of the hole. The image is provided 710 to machine vision software. The hole and the coating are located 712 in the image. Visual features for depletion and oxidation are located 714 using a deep learning algorithm. The depletion and oxidation of the visual features are evaluated 716. The evaluation results are presented 718. The example automated method 700 is capable of evaluating and / or repairing quickly and cost-effectively.

[0057] The multi-layer component part can be loaded 702 using any suitable loading technique known in the art that facilitates the success of the methods described herein. In some embodiments, the multi-layer component part is received at the manipulator. In some embodiments, the multi-layer component part is provided to the manipulator. In some embodiments, the manipulator approaches one or more predetermined points of the multi-layer component part.

[0058] The manipulator can be any suitable loading manipulator known in the art that facilitates the success of the methods described herein. In some embodiments, the manipulator is a robotic arm manipulator. In some embodiments, the manipulator is fully automated. In some embodiments, the manipulator is partially automated.

[0059] The manipulator uses a variety of tools. The tools can be in the form of a single tool, a device including the tool, and / or a tool attachment. These tools can be integrated with the manipulator and / or be readily available to the manipulator. For example, the manipulator can have a drilling device attachment for drilling, a polishing device attachment for polishing and preparation, and an imaging device attachment for imaging. Each of these tools can be used sequentially or simultaneously. In cases where the tool is not integrated with the manipulator, the manipulator can replace one tool with another. The manipulator can replace or switch tools at any point in the method.

[0060] The manipulator drills 704 holes in the multi-layer component. In some embodiments, the manipulator machines the surface of the multi-layer component part to produce a hole with a desired shape at a defined depth. The shape can be any shape, including circular, regular or irregular polygon, square, rectangle, triangle, pentagon, hexagon, heptagon, or octagon. In some embodiments, the manipulator machines the surface of the multi-layer component part to produce a hole at a predefined location. The predefined hole shape is deep enough to reach the substrate material and its size is set to reveal all the coatings.

[0061] After drilling, the manipulator uses 706 the polishing device to clean the machined surface and prepare it for inspection. The polishing device removes debris from the hole. The polishing device can also apply an etchant.

[0062] After preparing the hole, the manipulator records 708 one or more images of the prepared surface. The one or more images can include a single still image in picture format or a series of images in video format. The one or more images can be recorded at the same viewing point or different viewing points. The one or more images can be recorded simultaneously or at different times.

[0063] The one or more recorded images are provided 710 to image processing software (e.g., machine vision software) which analyzes the one or more images using algorithms. The algorithms can be any suitable algorithms known in the art that facilitate the success of the methods described herein. In some embodiments, the algorithms are artificial intelligence algorithms, machine learning algorithms, deep learning algorithms, or combinations thereof.

[0064] The image processing software can perform any suitable analysis known in the art that facilitates the success of the methods described herein. In some embodiments, the image processing software analyzes the one or more images to locate 712 the holes and coatings, locate 714 visual features for depletion and oxidation, and / or evaluate 716 depletion and oxidation.

[0065] After analysis, the image processing software generates and / or presents a report 718 that includes the analysis results. The report can be generated manually or through automation. In some embodiments, the report includes information related to the depletion and / or oxidation being evaluated. In some embodiments, the report includes a determination of pass or fail for a multi-layer component part. For example, if the multi-layer component part exhibits depletion and / or oxidation that exceeds a predefined standard, the report can indicate the fail status of the multi-layer component part.

[0066] The foregoing figures illustrate some associated processes in accordance with several embodiments of the present disclosure. In this regard, it should also be noted that in some alternative specific implementations, the described actions may not occur in the order indicated, or for example may actually be executed substantially simultaneously or in the reverse order, depending on the actions involved. Moreover, those of ordinary skill in the art will recognize that additional steps may be added to describe the process.

[0067] The terms used herein are for the purpose of describing particular embodiments only and are not intended to limit the present disclosure. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that when used in the specification, the terms "comprises" and / or "comprising" specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. "Optional" or "optionally" means that the subsequent described event or circumstance may or may not occur, and the description includes instances where the event occurs and instances where the event does not occur.

[0068] As used throughout the specification and claims, approximate language may be used to modify any quantitative representation that can permit variation without resulting in a change in the basic function associated therewith. Thus, values modified by one or more terms, such as "about", "approximately", and "substantially", are not limited to the precise values specified. In at least some instances, the approximate language may correspond to the precision of the instrument used to measure the value. Herein and throughout the specification and claims, range limitations may be combined and / or interchanged, such ranges are identified and include all the subranges subsumed therein, unless the context or language indicates otherwise. "About" applied to a particular value in a range applies to both values, and may indicate + / - 10% of the stated value, unless otherwise dependent on the precision of the instrument measuring the value.

[0069] All structural, material, acts, and equivalents of the apparatus or step plus function elements in the following claims are intended to include any structure, material, or act for performing the function in combination with other claimed elements that are claimed specifically. The description of the present disclosure has been given for purposes of illustration and description, but is not intended to be exhaustive or to limit the disclosure to the disclosed form. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The embodiments were chosen and described in order to best explain the principles of the disclosure and its practical application, and to enable others of ordinary skill in the art to understand the disclosure in various embodiments with various modifications that are suited to the particular use contemplated.

[0070] Other aspects of the present disclosure are provided by the subject matter of the following clauses:

[0071] 1. A method for analyzing the layer thickness of a multi-layer component, the method comprising:

[0072] Forming an opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component includes a plurality of material layers, the plurality of material layers including a substrate and a bond coat, and the opening exposes each of the plurality of material layers including the substrate;

[0073] Using a digital microscope to create an image of the plurality of exposed material layers in the opening; and

[0074] Calculating at least the thickness of the bond coat of the plurality of exposed material layers based on the image and based on the predefined geometry of the opening.

[0075] 2. The method according to any one of the preceding clauses, wherein the bond coat includes MrCrAlY, and the plurality of material layers further includes a depletion layer on the bond coat, and

[0076] The method further includes determining the thickness of the depletion layer.

[0077] 3. The method according to any one of the preceding clauses, further comprising determining the expected life of the bond coat based on at least one of the thickness of the depletion layer and the thickness of the bond coat.

[0078] 4. The method according to any one of the preceding clauses, wherein the plurality of material layers further includes an oxide layer on the depletion layer.

[0079] 5. The method according to any one of the preceding clauses, wherein the opening is formed to include drilling to form a tapered hole.

[0080] 6. The method according to any of the preceding clauses further comprises increasing the contrast uniquely in the exposed plurality of material layers in the opening from the increased contrast presented after the formation of the opening.

[0081] 7. The method according to any of the preceding clauses, wherein increasing the contrast comprises:

[0082] polishing the exposed plurality of material layers; and

[0083] etching the exposed plurality of material layers.

[0084] 8. The method according to any of the preceding clauses, wherein the polishing comprises using a felt with diamond abrasive paste, and the etching comprises using an etchant.

[0085] 9. The method according to any of the preceding clauses, wherein the plurality of material layers comprises an oxide layer on the bond coat and the bond coat on the substrate.

[0086] 10. The method according to any of the preceding clauses further comprises repairing the opening so as to allow the multi-layer component to be used for its intended purpose.

[0087] 11. The method according to any of the preceding clauses, wherein prior to the drilling, the multi-layer component further comprises a thermal barrier coating (TBC) layer on the oxide layer, and the method further comprises removing at least a portion of the TBC layer prior to the drilling, and wherein the repair comprises repairing at least a portion of the TBC layer.

[0088] 12. The method according to any of the preceding clauses, wherein the method is performed prior to the use of the multi-layer component.

[0089] 13. The method according to any of the preceding clauses, wherein prior to the drilling, the multi-layer component further comprises a thermal barrier coating (TBC) layer on the bond coat, and the method further comprises removing at least a portion of the TBC layer prior to the drilling, and wherein the repair comprises repairing at least a portion of the TBC layer.

[0090] 14. The method according to any of the preceding clauses, wherein the method is performed at the geographical location of the use site of the multi-layer component.

[0091] 15. The method according to any of the preceding clauses, wherein repairing the opening comprises using at least one handheld device.

[0092] 16. A multi-layer component, comprising:

[0093] a substrate;

[0094] A bond coat on the substrate;

[0095] A thermal barrier coating (TBC) layer on the bond coat, the TBC layer having a first outer surface that shows signs of exposure to a hot gas path environment; and

[0096] Filled openings located in the substrate, the bond coat, and the TBC layer, the filled openings comprising:

[0097] A substrate repair filler that fills the filled opening located in the substrate,

[0098] A bond coat repair filler that fills the filled opening located in the bond coat, and

[0099] A thermal barrier coating (TBC) plug that fills the filled opening located in the TBC layer, the TBC plug having a second outer surface that does not show signs of exposure to the hot gas path environment or shows fewer signs of exposure to the hot gas path environment than the first outer surface.

[0100] 17. The multi-layer component according to any one of the preceding clauses, wherein the substrate repair filler that fills the filled opening in the substrate is the same material as the bond coat repair filler that fills the filled opening in the bond coat.

[0101] 18. A method of analyzing the layer thickness of a multi-layer component, the method comprising:

[0102] Drilling an opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component comprises a plurality of material layers, the plurality of material layers including a substrate and a bond coat on the substrate, and wherein the opening exposes each of the plurality of material layers;

[0103] By polishing and etching the exposed plurality of material layers, increasing the contrast that uniquely appears in the exposed plurality of material layers in the opening after the opening is formed;

[0104] Using a digital microscope to create an image of the exposed plurality of material layers in the opening;

[0105] Calculating the thickness of the bond coat based on the image and based on the predefined geometry of the opening; and

[0106] Repairing the opening so as to allow the multi-layer component to be used for its intended purpose.

[0107] 19. The method according to any one of the preceding clauses, wherein the method is performed at the geographical location of the use site of the multi-layer component.

[0108] 20. The method according to any one of the preceding clauses, wherein prior to the drilling, the multi-layer component further comprises a thermal barrier coating (TBC) layer on the oxide layer, and the method further comprises removing the TBC layer prior to the drilling, and wherein the repair comprises repairing the TBC layer.

[0109] 21. A system for analyzing the layer thickness of a multi-layer component, the system comprising:

[0110] An opening forming device configured to form an opening having a predefined geometry that partially enters the multi-layer component at a selected position on the surface of the multi-layer component, wherein the multi-layer component comprises a plurality of material layers, the plurality of material layers comprising at least a substrate and a bond coat, and wherein the opening exposes each of the plurality of material layers; and

[0111] An imaging device configured to create an image of the plurality of exposed material layers in the opening;

[0112] Wherein the system is configured to calculate at least the thickness of the bond coat of the plurality of exposed material layers based on the image and based on the predefined geometry of the opening.

[0113] 22. The system according to any one of the preceding clauses, wherein the plurality of material layers further comprises a depletion layer extending over the bond coat, and the system is further configured to determine the thickness of the depletion layer.

[0114] 23. The system according to any one of the preceding clauses, wherein the system is further configured to determine the expected life of the bond coat based on at least one of the thickness of the depletion layer and the thickness of the bond coat.

[0115] 24. The system according to any one of the preceding clauses, further comprising a contrast enhancing device configured to increase the contrast of the plurality of exposed material layers in the opening.

[0116] 25. The system according to any one of the preceding clauses, wherein the contrast enhancing device is selected from the group consisting of a polisher, a felt with diamond paste, an etchant, an electrochemical etchant, and combinations thereof.

[0117] 26. The system according to any one of the preceding clauses, further comprising a TBC layer removing device.

[0118] 27. The system according to any one of the preceding clauses, wherein the TBC layer removing device is a shot blaster or a sand blaster.

[0119] 28. The system according to any one of the preceding clauses, wherein the opening forming device is selected from the group consisting of a drilling device, a dome grinding device, a material removal tool, a milling tool, and combinations thereof.

[0120] 29. The system according to any one of the preceding clauses, wherein the imaging device is a microscope.

[0121] 30. The system according to any one of the preceding clauses, wherein the imaging device is handheld and portable.

[0122] 31. A system for repairing a multi-layer component, the system comprising:

[0123] An opening forming device configured to form an opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component includes a plurality of material layers, the plurality of material layers including at least a substrate and a bond coat, and wherein the opening exposes each of the plurality of material layers;

[0124] An imaging device configured to create an image of the plurality of exposed material layers in the opening; and

[0125] A repair device configured to repair the opening;

[0126] Wherein the system is configured to calculate at least the thickness of the bond coat of the plurality of exposed material layers based on the image and based on the predefined geometry of the opening before the repair of the opening.

[0127] 32. The system according to any one of the preceding clauses, further comprising a contrast enhancing device configured to increase the contrast of the plurality of exposed material layers in the opening.

[0128] 33. The system according to any one of the preceding clauses, wherein the contrast enhancing device is selected from the group consisting of a polisher, a felt with diamond paste, an etchant, an electrochemical etchant, and combinations thereof.

[0129] 34. The system according to any one of the preceding clauses, wherein the repair device is a handheld device.

[0130] 35. The system according to any of the preceding clauses, wherein the repair device is configured for high velocity oxygen fuel (HVOF) coating, low pressure plasma spraying (LPPS), and / or air plasma spraying (APS).

[0131] 36. The system according to any of the preceding clauses, wherein the repair device is selected from the group consisting of a laser wire welding device, a tungsten inert gas (TIG) welding device, a thermal spraying process device, an air plasma spraying (APS) device, a flame spraying device, a slurry coating device, and combinations thereof.

[0132] 37. The system according to any of the preceding clauses, wherein the repair device is configured to receive a multi-layer component that has been disassembled from the operating environment.

[0133] 38. The system according to any of the preceding clauses, wherein the operating environment is inside a turbine.

[0134] 39. The system according to any of the preceding clauses, wherein the multi-layer component is for use in an airfoil.

[0135] 40. The system according to any of the preceding clauses, wherein the multi-layer component is for use in a turbine blade.

[0136] 41. An automated system for analyzing the layer thickness of a multi-layer component, the automated system comprising:

[0137] A manipulator coupled to:

[0138] An opening forming device configured to form an opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component includes a plurality of material layers, the plurality of material layers including at least a substrate and a bond coat, and wherein the opening exposes each of the plurality of material layers; and

[0139] An imaging device configured to create an image of the plurality of exposed material layers in the opening; and

[0140] A processor configured to calculate at least the thickness of the bond coat of the plurality of exposed material layers based on the image and based on the predefined geometry of the opening.

[0141] 42. The automated system according to any of the preceding clauses, wherein the plurality of material layers further includes a depletion layer extending over the bond coat, and the processor is further configured to determine the thickness of the depletion layer.

[0142] 43. The automated system according to any one of the preceding clauses, wherein the processor is further configured to determine the expected life of the bonding coating based on at least one of the thickness of the depletion layer and the thickness of the bonding coating.

[0143] 44. The automated system according to any one of the preceding clauses, wherein at least one of the opening forming device and the imaging device is coupled to the manipulator in the form of an attachment attached to the manipulator.

[0144] 45. The automated system according to any one of the preceding clauses, wherein at least one of the opening forming device and the imaging device is coupled to the manipulator in the form of a tool separate from the manipulator.

[0145] 46. The automated system according to any one of the preceding clauses, wherein the manipulator is further coupled to at least one of a contrast enhancing device, a repair device, and a TBC layer removal device, the contrast enhancing device being configured to increase the contrast of the plurality of exposed material layers in the opening, the repair device being configured to repair the opening.

[0146] 47. The automated system according to any one of the preceding clauses, wherein at least one of the contrast enhancing device, the repair device, and the TBC layer removal device is coupled to the manipulator in the form of an attachment attached to the manipulator.

[0147] 48. The automated system according to any one of the preceding clauses, wherein at least one of the contrast enhancing device, the repair device, and the TBC layer removal device is coupled to the manipulator in the form of a tool separate from the manipulator.

[0148] 49. The automated system according to any one of the preceding clauses, further comprising a controller and / or a power supply.

[0149] 50. The automated system according to any one of the preceding clauses, wherein the manipulator is configured to receive a multi-layer component that has been disassembled from the use environment.

[0150] 51. The automated system according to any one of the preceding clauses, wherein the use environment is inside a turbine.

[0151] 52. The automated system according to any one of the preceding clauses, wherein the multi-layer component is for use in an airfoil.

[0152] 53. The automated system according to any one of the preceding clauses, wherein the multi-layer component is for use in a turbine blade.

[0153] 54. A method for analyzing the layer thickness of a multi-layer component using an automated system including a manipulator and a processor, the method comprising:

[0154] Receiving the multi-layer component at the manipulator of the automated system;

[0155] Forming an opening using an opening forming device coupled to the manipulator, the opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component includes a plurality of material layers, the plurality of material layers at least including a substrate and a bonding coating, and wherein the opening exposes each of the plurality of material layers;

[0156] Creating an image of the exposed plurality of material layers in the opening using an imaging device coupled to the manipulator; and

[0157] Calculating at least the thickness of the bonding coating of the exposed plurality of material layers by the processor of the automated system based on the image and based on the predefined geometry of the opening.

[0158] 55. The method according to any one of the preceding clauses, wherein the plurality of material layers further includes a depletion layer extending over the bonding coating, and wherein the method further includes determining the thickness of the depletion layer.

[0159] 56. The method according to any one of the preceding clauses, further comprising determining the expected life of the bonding coating based on at least one of the thickness of the depletion layer and the thickness of the bonding coating.

[0160] 57. A method for repairing a multi-layer component using an automated system including a manipulator and a processor, the method comprising:

[0161] Receiving the multi-layer component at the manipulator of the automated system;

[0162] Forming an opening using an opening forming device coupled to the manipulator, the opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component includes a plurality of material layers, the plurality of material layers at least including a substrate and a bonding coating, and wherein the opening exposes each of the plurality of material layers;

[0163] Creating an image of the exposed plurality of material layers in the opening using an imaging device coupled to the manipulator;

[0164] Using the processor of the automated system, calculate at least the thickness of the bond coat of the plurality of material layers exposed based on the image and based on the predefined geometry of the opening; and

[0165] Repair the opening using the repair device of the manipulator coupled to the automated system.

[0166] 58. The method according to any one of the preceding clauses, wherein the plurality of material layers further comprises a depletion layer extending over the bond coat, and wherein the method further comprises determining the thickness of the depletion layer.

[0167] 59. The method according to any one of the preceding clauses, further comprising determining the expected life of the bond coat based on at least one of the thickness of the depletion layer and the thickness of the bond coat.

[0168] 60. The method according to any one of the preceding clauses, wherein prior to forming the opening, the multi-layer component further comprises a thermal barrier coating (TBC) layer extending over the oxide layer, wherein the method further comprises removing the TBC layer prior to forming the opening, and wherein the repair comprises repairing the TBC layer.

Claims

1. An automated system for analyzing the layer thickness of a multi-layer component, the automated system comprising: A manipulator, the manipulator being coupled to: An opening forming device configured to form an opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component comprises a plurality of material layers, the plurality of material layers including at least a substrate and a bond coat, and wherein the opening exposes each of the plurality of material layers; And An imaging device configured to create an image of the exposed plurality of material layers in the opening; And A processor configured to calculate at least the thickness of the bond coat of the exposed plurality of material layers based on the image and based on the predefined geometry of the opening.

2. The automated system according to claim 1, wherein the plurality of material layers further comprises a depletion layer extending over the bond coat, and the processor is further configured to determine the thickness of the depletion layer.

3. The automated system according to claim 2, wherein the processor is further configured to determine the expected life of the bond coat based on at least one of the thickness of the depletion layer and the thickness of the bond coat.

4. The automated system according to claim 1, wherein at least one of the opening forming device and the imaging device is coupled to the manipulator in the form of an attachment attached to the manipulator.

5. The automated system according to claim 1, wherein at least one of the opening forming device and the imaging device is coupled to the manipulator in the form of a tool separate from the manipulator.

6. The automated system according to claim 1, wherein the manipulator is further coupled to at least one of a contrast enhancement device, a repair device, and a TBC layer removal device, the contrast enhancement device being configured to increase the contrast of the exposed plurality of material layers in the opening, the repair device being configured to repair the opening.

7. The automated system according to claim 6, wherein at least one of the contrast enhancement device, the repair device, and the TBC layer removal device is coupled to the manipulator in the form of an attachment attached to the manipulator.

8. The automated system according to claim 6, wherein at least one of the contrast enhancement device, the repair device, and the TBC layer removal device is coupled to the manipulator in the form of a tool separate from the manipulator.

9. The automated system according to claim 1, further comprising a controller and / or a power supply.

10. The automated system according to claim 1, wherein the manipulator is configured to receive a multi-layer component that has been disassembled from a service environment.

11. The automated system according to claim 10, wherein the service environment is inside a turbine.

12. The automated system according to claim 10, wherein the multi-layer component is for use in an airfoil.

13. The automated system according to claim 10, wherein the multi-layer component is for use in a turbine blade.

14. A method for analyzing the layer thickness of a multi-layer component using an automated system including a manipulator and a processor, the method comprising: Receiving the multi-layer component at the manipulator of the automated system; Forming an opening using an opening forming device coupled to the manipulator, the opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component includes a plurality of material layers, the plurality of material layers including at least a substrate and a bond coat, and wherein the opening exposes each of the plurality of material layers; Creating an image of the exposed plurality of material layers in the opening using an imaging device coupled to the manipulator; And Calculating at least the thickness of the bond coat of the exposed plurality of material layers using the processor of the automated system based on the image and based on the predefined geometry of the opening.

15. The method according to claim 14, wherein the plurality of material layers further includes a depletion layer extending over the bond coat, and wherein the method further includes determining the thickness of the depletion layer.

16. The method according to claim 15, further comprising determining the expected life of the bond coat based on at least one of the thickness of the depletion layer and the thickness of the bond coat.

17. A method for repairing a multi-layer component using an automated system including a manipulator and a processor, the method comprising: Receiving the multi-layer component at the manipulator of the automated system; Forming an opening using an opening forming device coupled to the manipulator, the opening having a predefined geometry that partially enters the multi-layer component at a selected location on the surface of the multi-layer component, wherein the multi-layer component includes a plurality of material layers, the plurality of material layers including at least a substrate and a bond coat, and wherein the opening exposes each of the plurality of material layers; Creating an image of the exposed plurality of material layers in the opening using an imaging device coupled to the manipulator; Calculating at least the thickness of the bond coat of the exposed plurality of material layers using the processor of the automated system based on the image and based on the predefined geometry of the opening; And Repairing the opening using a repair device coupled to the manipulator of the automated system.

18. The method according to claim 17, wherein the plurality of material layers further includes a depletion layer extending over the bond coat, and wherein the method further includes determining the thickness of the depletion layer.

19. The method according to claim 18, further comprising determining the expected life of the bond coat based on at least one of the thickness of the depletion layer and the thickness of the bond coat.

20. The method according to claim 17, wherein prior to forming the opening, the multi-layer component further includes a thermal barrier coating (TBC) layer extending over the oxide layer, wherein the method further includes removing the TBC layer prior to forming the opening, and wherein the repair includes repairing the TBC layer.

Images