Electromagnetic inspection system and method

Abstract

In some embodiments, a system for evaluating a coating (e.g., a thermal barrier coating) includes an electromagnetic inspection device and a controller in operable communication with the electromagnetic inspection device. The electromagnetic inspection device comprises an electromagnetic radiation source and a detector. The electromagnetic radiation source generates pulsed electromagnetic radiation that penetrates a coating of a component of the engine. The detector receives reflected electromagnetic radiation reflected from the component. The controller is configured to receive an electromagnetic radiation waveform indicative of reflected electromagnetic radiation. The controller is further configured to determine a property of the coating based on the electromagnetic radiation waveform and determine a remaining life of the coating based on the property. The controller may also be configured to communicate control commands to the engine based on the remaining life.

Description

Technical Field

[0001] These teachings generally relate to the inspection of components, and more particularly to the inspection of coatings thereof. Background Art

[0002] Various protective coatings can be used to protect components. Protective coatings can include thermal barrier coatings, which help protect parts that operate at high temperatures, such as internal parts of aircraft turbine engines. However, protective coatings can be subject to penetration by foreign materials such as calcium magnesium aluminum silicate (CMAS). CMAS can originate from siliceous debris such as sand or volcanic ash that can be ingested into aircraft turbine engines. At high temperatures, CMAS can melt and penetrate protective coatings on components of aircraft turbine engines. CMAS penetration can degrade the protective coating on the component, thereby damaging the underlying component. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Various needs are met, at least in part, by providing the electromagnetic inspection systems and methods described in the following detailed description, particularly when studied in conjunction with the accompanying drawings. A complete and enabling disclosure of the various aspects of the present description, including the best mode thereof, is set forth in the specification with reference to the accompanying drawings, wherein:

[0004] Figure 1 is a block diagram of an electromagnetic inspection system for detecting at least one of a condition or a remaining life of a coating according to various embodiments of these teachings;

[0005] Figure 2 is a schematic diagram of exemplary components and electromagnetic inspection apparatus according to various embodiments of these teachings;

[0006] Figure 3 is a flow chart of an exemplary inspection method according to various embodiments of these teachings;

[0007] Figure 4A 、 4B and 4C show various embodiments according to these teachings via Figure 1 Exemplary data obtained by the electromagnetic inspection system;

[0008] Figure 5 is a graph of transmission time as a function of the percentage of penetration of CMAS in the coating; and

[0009] Figure 6 is a graph showing the percentage change in detectable CMAS as a function of CMAS thickness.

[0010] The elements in the figures are shown for simplicity and clarity and are not necessarily drawn to scale. For example, the size and / or relative positioning of certain elements in the figures may be exaggerated relative to other elements to help improve understanding of the various embodiments of the present teachings. In addition, common but easy-to-understand elements that are useful or necessary in commercially feasible embodiments are generally not depicted to facilitate viewing these various embodiments of the present teachings with less obstruction. Certain actions and / or steps may be described or depicted in a specific order of occurrence, and those skilled in the art will understand that such specificity about the order is not actually required. DETAILED DESCRIPTION

[0011] The methods provided herein use electromagnetic radiation (e.g., in the terahertz range) to probe a coated part to determine the remaining life of the coating and / or the level of penetration of foreign matter (e.g., CMAS). The coating is probed with pulsed electromagnetic radiation reflected from the coating. The reflected electromagnetic radiation can then be evaluated, for example, to determine changes in the waveform of the electromagnetic radiation. For example, the peak value of the reflected electromagnetic radiation waveform may be different between a permeable coating and a non-permeable coating. Therefore, the systems and methods described herein use reflected electromagnetic radiation waveforms to evaluate the coating, in particular to determine the remaining life of the coating. The systems and methods described herein can also use reflected electromagnetic radiation waveforms to determine the condition of the coating, such as the level of penetration of foreign matter, the thickness of the coating, and / or whether foreign matter has penetrated and / or deposited on the coating.

[0012] Traditional methods for determining the remaining life of a coating or determining the level of penetration of foreign matter (e.g., CMAS) into a coating may involve destructive testing. For example, a part may be cut to inspect the coating integrity and the amount of coating remaining on the part. In this approach, the part may not be returned to service, but may be scrapped and replaced, which is both expensive and time-consuming. In general, the systems and methods described herein provide a non-destructive method for evaluating coatings on parts. The methods described herein can be used to evaluate coatings without having to contact, destroy, or prepare the part. Because the part is not destroyed using the methods described herein, the part can be returned to service for continued use. Therefore, the methods described herein can reduce costs and time compared to traditional destructive methods.

[0013] In some embodiments, the systems and methods provided herein can be used to evaluate thermal barrier coatings. However, it is contemplated that these systems and methods can be applied to any protective coating. In some embodiments, these systems and methods can be used to evaluate dielectric coatings. As used herein, refractive index can refer to a coating having a refractive index (RI) in the range of about 3.0 to about 5.2.

[0014] In some aspects, an inspection system includes an electromagnetic inspection device and a controller. The electromagnetic inspection device includes an electromagnetic radiation source for generating pulsed electromagnetic radiation that penetrates a coating of a component (e.g., a component of an engine). In some methods, the electromagnetic radiation source generates pulsed electromagnetic radiation in the terahertz frequency range. The electromagnetic inspection device also includes a detector for receiving reflected electromagnetic radiation reflected from the component. The controller is in operable communication with the electromagnetic inspection device. The controller is configured to receive an electromagnetic radiation waveform representing the reflected electromagnetic radiation. The controller is further configured to determine a property of the coating based on the electromagnetic radiation waveform. In some methods, the property of the coating is a dielectric property of the coating or material loss from the coating. The controller is further configured to determine the remaining life of the coating based on the property and update a model of the engine based on the remaining life of the coating. In some methods, the controller can be further configured to determine the condition of the coating based on the property of the coating, such as the level of foreign matter penetration. In this method, the controller can determine the remaining life based on the condition of the coating.

[0015] In some aspects, a method includes directing pulsed electromagnetic radiation through a coating of a component (e.g., a component of an engine) at an electromagnetic radiation source. The method also includes receiving, at a detector, reflected electromagnetic radiation reflected from at least one of the coating or the component. The method also includes determining a property of the coating based on the reflected electromagnetic radiation. The method further includes determining a remaining lifespan of the coating based on the property, and adjusting operation or maintenance of the engine based on the remaining lifespan.

[0016] Referring now to the drawings, in particular Figure 1 , presents a system 100 compatible with many of these teachings. System 100 is an electromagnetic inspection system that can be used to inspect or monitor a component 102. Component 102 can be a component of an engine 104 (e.g., a gas turbine engine used in an aircraft). For example, component 102 can be a turbine blade or a turbine nozzle of engine 104. Component 102 has one or more coatings 112. In some examples, one or more coatings 112 are thermal barrier coatings, such as yttria-stabilized zirconia.

[0017] System 100 includes an electromagnetic inspection device 106 and a controller 108 in communication via a network 150. System 100 may also include one or more databases 110 in communication with one or more of electromagnetic inspection device 106 and controller 108.

[0018] Electromagnetic inspection device 106 includes a radiation source 118 and a detector 120. According to some embodiments, Figure 2A schematic diagram of electromagnetic inspection device 106 is shown. However, it is contemplated that radiation source 118 and detector 120 of electromagnetic inspection device 106 may have any suitable configuration that directs electromagnetic radiation toward component 102 and detects electromagnetic radiation reflected from component 102.

[0019] Radiation source 118 emits, transmits, or generates electromagnetic pulses of electromagnetic radiation that penetrate coating 112 of component 102. Radiation source 118 can generate pulses of electromagnetic radiation in any suitable frequency range, and in some aspects, generates pulses of electromagnetic radiation in the terahertz frequency range. Pulsed electromagnetic radiation can penetrate coating 112 with minimal scattering. As used herein, the terahertz frequency range refers to frequencies between approximately 0.1 terahertz (THz) and approximately 10 THz. In some aspects, the coating thickness can be determined from the pulse data. Radiation source 118 can be any suitable radiation source or excitation source that generates or emits electromagnetic radiation. Suitable radiation sources include, for example, lasers or molecular lasers. In some examples, radiation source 118 includes multiple radiation sources. In some examples, component 102 is metal, which serves as a substrate for coating 112. Metal is opaque to the terahertz frequency range and therefore reflects terahertz radiation, making it easier to measure the reflection of electromagnetic radiation.

[0020] Detector 120 detects or receives electromagnetic waves emitted from radiation source 118. In some aspects, detector 120 detects electromagnetic waves emitted from the radiation source and reflected from a sample (e.g., component 102 or a portion thereof, such as coating 112). Detector 120 can be any suitable device capable of receiving, measuring, quantifying, or otherwise detecting electromagnetic waves or electromagnetic radiation generated by, for example, a photoconductive antenna, a nonlinear crystal material, or the like. Detector 120 can convert incoming electromagnetic waves or radiation into an electrical measurement signal indicative of incoming reflected electromagnetic radiation. In some examples, detector 120 can include multiple detectors.

[0021] Controller 108 receives data from electromagnetic detection device 106. For example, controller 108 may receive electromagnetic radiation data in the form of electrical measurement signals from electromagnetic detection device 106, and in particular, from detector 120. The electromagnetic radiation data may include any data related to the waveform of electromagnetic waves reflected from a sample (e.g., component 102 or coating 112). In some examples, the electromagnetic radiation data is an electromagnetic radiation waveform. It is contemplated that controller 108 may be configured to perform one or more of the methods described herein, or portions thereof.

[0022] The controller 108 can be used as a computing device to perform the functions and methods described herein. The controller 108 can include one or more processors 128, input / output (I / O) devices 130, and a memory device 122. The processor 128 can include any suitable processing device, such as a microprocessor, a microcontroller, an integrated circuit, a logic device, or other suitable processing device. The processor 128 can be used to perform or assist in performing the steps of the processes, methods, functions, and techniques described herein, and to control various communications, decisions, programs, content, lists, services, interfaces, logging, reporting, etc. In addition, the one or more processors 128 can access the memory device 122, which can store instructions 126, code, etc., which are executed by the processor 128 to perform the intended functions.

[0023] The memory device 122 generally includes one or more processor-readable and / or computer-readable media accessed by at least the processor 128, and may include volatile and / or non-volatile media, such as RAM, ROM, EEPROM, flash memory, and / or other memory technologies. Additionally, the memory device 122 is shown as being internal to the controller 108; however, the memory device 122 may be internal memory, external memory, or a combination of internal and external memory. Similarly, some or all of the memory devices 122 may be internal memory, external memory, or a combination of internal and external memory of the processor 128. The memory device 122 may be substantially any relevant memory, such as, but not limited to, a solid-state storage device or drive, a hard drive, one or more Universal Serial Bus (USB) sticks or drives, a flash secure digital (SD) card, other memory cards, and other such memory, or a combination of two or more such memories, and some or all of the memory may be distributed across multiple locations on a computer network. The memory device 122 may store data 124, such as code, software, executable files, scripts, data, content, lists, programming, programs, log or historical data, engine information, component information, and the like. While Figure 1 The various components are shown coupled together via a bus, but it is understood that the various components may actually be coupled directly to the controller 108 and / or one or more other components.

[0024] I / O device 130 may be any relevant port or combination of ports, such as, but not limited to, a USB, Ethernet, or other such port. I / O device 130 may be configured to allow for wired and / or wireless communication to external components. For example, I / O device 130 may provide wired and / or wireless communication (e.g., Wi-Fi, Bluetooth, cellular, RF, and / or other such wireless communications), and in some cases may include any suitable wired and / or wireless interface devices, circuits, and / or connection devices, such as, but not limited to, one or more transmitters, receivers, transceivers, or a combination of two or more of such devices.

[0025] In some approaches, the controller 108 can be configured to determine a property of the coating 112 and / or the component 102 based on the electromagnetic radiation data (e.g., based on characteristics of the reflected electromagnetic radiation waveform). The property of the coating 112 can be a dielectric property of the coating. The dielectric property of the coating 112 can affect the manner in which electromagnetic radiation travels through the coating 112. For example, the refractive index of the coating 112 can change as the condition of the coating (e.g., the level of foreign matter penetration) changes. Thus, the property of the coating 112 can be correlated with the condition of the coating, which can then be used to determine the remaining life of the coating. In some approaches, the controller 108 compares the property or condition of the coating 112 to a threshold value to determine the remaining life of the coating 112 and whether the coating 112 is suitable for continued service.

[0026] Controller 108 may be configured to determine a remaining lifespan of one or more of coating 112 and / or component 102 based on the properties of coating 112. In some embodiments, controller 108 is configured to determine the remaining lifespan of coating 112 based on calibration data. The calibration data may include a relationship between the properties of coating 112 and the remaining lifespan of coating 112.

[0027] In some embodiments, the controller 108 is further configured to determine or assess a condition of the coating 112 based on properties of the coating 112. In one example, the condition of the coating 112 is a level of foreign matter penetration of the coating 112. The remaining life of the coating 112 may then be based on the condition of the coating 112. For example, the controller 108 may be configured to determine the remaining life based on calibration data that includes a relationship between the condition of the coating 112 and the remaining life of the coating 112.

[0028] In some embodiments, controller 108 is further configured to compare electromagnetic radiation data (e.g., electromagnetic radiation waveform) with baseline data. For example, controller 108 compares the electromagnetic radiation data with the baseline data by determining a ratio of the electromagnetic radiation data to the baseline data. The baseline data may indicate electromagnetic radiation reflected from the component in a previous state. Thus, controller 108 may determine a change in the electromagnetic radiation data, such as a change in the electromagnetic radiation waveform. Controller 108 may then determine the remaining life of the coating based on the comparison of the electromagnetic radiation data with the baseline data. In some examples, the baseline data is stored in memory device 122 and / or database 110.

[0029] In some embodiments, the controller 108 is configured to compare the remaining life of the coating to a threshold value. The controller 108 can then determine an action for the engine 104 when it determines that the remaining life of the coating is below the threshold value. In some examples, the threshold value is stored in the memory device 122 and / or the database 110.

[0030] The controller 108 may also be configured to update the model of the engine 104 based on the remaining life of the coating 112. An engine or fleet of engines may have one or more associated models, such as models of wear or degradation of the engine or its components, operating characteristics, and the like. In one example, the controller 108 may update such a model of the engine to more closely correspond to real-world observations during an inspection. In one example, if, based on an inspection conducted via the systems and methods described herein, the controller 108 determines that the remaining life reflects a faster rate of degradation of the coating 112 than modeled, the controller 108 may adjust the model to align with the remaining life determined by the controller 108. In this manner, the engine model may be customized based on real-world performance determined by the inspection systems and methods described herein. In some examples, the model of the engine 104 may be stored in the memory device 122. In other examples, the model may be stored in a memory or other external data system in communication with the controller 108.

[0031] Furthermore, controller 108 may be configured to determine an action for engine 104 based on the remaining life. In some approaches, controller 108 may be configured to compare the remaining life of the coating to a threshold. The controller may determine an action for engine 104 upon determining that the remaining life of coating 112 is below the threshold. The action may include, for example, reducing the power rating of engine 104, repairing component 102, replacing component 102 or coating 112, cleaning component 102, adjusting the route of an aircraft powered by the engine, or changing the payload used by engine 104. These actions may adjust the operation of the engine in a manner more appropriate for the component indicated by the remaining life. For example, when the remaining life is short, the action may be to relocate the engine to a less harsh operating environment. In some embodiments, controller 108 may communicate control commands to engine 104 to implement or execute the action for engine 104. Controller 108 may also communicate the action to a user of engine 104, for example, via a user interface.

[0032] In one example, the controller 108 communicates with the engine operating system 114. As such, the controller 108 can communicate actions to the engine operating system 114 to adjust the operation of the engine 104. For example, the control commands can adjust the operation of the engine 104 by reducing the power rating of the engine 104, adjusting the route of the aircraft powered by the engine 104, or changing the payload for the engine 104.

[0033] In another example, the controller 108 communicates with a user interface device 116 associated with the engine 104. In this manner, the controller 108 can communicate or send an alert or electronic message to the user interface device 116 for use by a user (e.g., an operator, technician, administrator, or owner of the engine 104). The controller 108 can send an alert or message to the user interface device 116 regarding a maintenance, repair, cleaning, or treatment action or plan. For example, the alert or message can relate to repairing, cleaning, decommissioning, or adding a new coating to a component 102 of the engine 104.

[0034] One or more databases 110 may communicate with one or more of electromagnetic inspection device 106 and controller 108 via network 150. Network 150 may communicate information to or from one of databases 110.

[0035] Database 110 may store data acquired by electromagnetic inspection device 106. Database 110 may store scan data 132. Scan data 132 may include any data acquired by electromagnetic inspection device 106 and any data related to parameters or settings of electromagnetic inspection device 106, for example, during a scan or inspection of component 102 or a portion thereof. Scan data 132 may include electromagnetic radiation data. The electromagnetic radiation data may be data regarding an electromagnetic radiation waveform or any other data related to electromagnetic radiation reflected from coating 112 or component 102. In some examples, the electromagnetic radiation data may include a travel time or time delay (e.g., when the data is in the frequency domain) between a peak 136 and a peak amplitude 138 of the waveform of the electromagnetic radiation reflected from coating 112 or component 102, or a peak electric field (e.g., E max 、E min ) (e.g., when the data is in the time domain).

[0036] The database 110 may also store any data received, determined, or otherwise useful to operations performed by the controller 108. For example, the database 110 may also store calculated data 134 calculated or determined by the controller 108. The calculated data 134 may include data regarding one or more of a property 140 of the coating, a measurement 142 of foreign matter penetration, and a remaining life 144 of the coating.

[0037] In some embodiments, the system 100 is in communication with the engine 104 or a component or system thereof. The system 100 may communicate one or more control commands to the engine 104 (or a component or system thereof) in response to determinations made by the controller 108 .

[0038] One or more components of system 100, including electromagnetic inspection device 106, controller 108, database 110, engine operating system 114, and user interface device 116, may communicate information with each other via network 150. Network 150 may be any suitable communication network, such as a LAN, WAN, Internet, cellular, Wi-Fi, and other such communication networks, or a combination of two or more of such networks.

[0039] Figure 2 is a schematic diagram of an electromagnetic inspection device 106 and component 102 according to some embodiments. Figure 2 In the illustrative example of FIG, component 102 includes a first coating 112A and a second coating 112B. First coating 112A may be, for example, a pristine thermal barrier coating or a thermal barrier coating infiltrated with CMAS. In some examples, first coating 112A may include multiple types of thermal barrier coatings (TBCs). Second coating 112B may be a CMAS buildup layer on top of the thermal barrier coating, for example, after the thermal barrier coating has been fully infiltrated with CMAS.

[0040] Radiation source 118 emits electromagnetic wave 152 toward component 102 to irradiate component 102. Electromagnetic wave 152 reflects from second coating 112B to generate reflected electromagnetic wave 154.

[0041] Detector 120 detects or receives reflected electromagnetic wave 154. Reflected electromagnetic wave 154 may include a first peak, which indicates an interface between air and second coating 112B (e.g., an air-CMAS interface). Reflected electromagnetic wave 154 may also include a second peak, which indicates an interface between second coating 112B and first coating 112A (e.g., a CMAS-thermal barrier coating interface). Reflected electromagnetic wave 154 may also include a third peak, which indicates an interface between first coating 112A and component 102 (e.g., a thermal barrier coating-component interface). Figure 4C Shown Figure 2 1. Example waveform of reflected electromagnetic wave 154 for component 102 having first coating 112A (eg, thermal barrier coating) and second coating 112B (eg, CMAS buildup) configured in FIG.

[0042] By analyzing the waveform of reflected electromagnetic wave 154, system 100 can determine one or more properties of first coating 112A and one or more properties of second coating 112B. For example, the waveform of the reflected electromagnetic wave may be related to one or more of the condition of the coating, the thickness of the coating, or the penetration of foreign matter, such as CMAS, into the coating.

[0043] Now go to Figure 3 , shows a method for inspecting a component. One or more steps of the method may be performed by Figure 1 The system 100 is executed.

[0044] At block 160, the electromagnetic inspection device directs pulsed electromagnetic radiation through a coating of a component of the engine. In some examples, the coating is a thermal barrier coating. The electromagnetic inspection device may direct the pulsed electromagnetic radiation through the coating at an electromagnetic radiation source of the electromagnetic inspection device. In some methods, radiation source 118 of electromagnetic inspection device 106 in system 100 directs electromagnetic radiation through coating 112 of component 102. In some examples, radiation source 118 is activated and / or otherwise controlled by controller 108.

[0045] At block 162, the electromagnetic detection device receives electromagnetic radiation reflected from at least one of the coating or the component. The electromagnetic detection device may receive the reflected electromagnetic radiation at a detector of the electromagnetic detection device. In some approaches, the reflected electromagnetic radiation is received by the detector 120 of the electromagnetic inspection device 106 in the system 100. The detector 120 may generate and / or communicate an electrical signal indicative of or representative of a waveform of the reflected electromagnetic radiation.

[0046] At box 164, the controller determines the properties of the coating based on the reflected electromagnetic radiation waveform. In some embodiments, the properties of the coating are the dielectric properties of the coating or the material loss from the coating. Examples of dielectric properties of the coating include refractive index (RI) or attenuation. Dielectric properties can refer to a combination of a real part and an imaginary part of the refractive index reflecting attenuation. The properties of the coating are at least partially related to energy loss in the coating, which may be related to the dielectric properties and scattering of the coating. The measured energy loss is, for example, due to absorption and / or scattering of electromagnetic radiation. The energy loss can be determined based on the extinction coefficient or the scattering coefficient. The properties of the coating can also be physical properties, such as coating thickness or coating density. In some methods, the controller 108 in the system 100 determines the properties of the coating based on the reflected electromagnetic radiation.

[0047] The controller can determine a property of the coating based on the reflected electromagnetic radiation waveform. The controller can perform a fast Fourier transform to construct a frequency domain representation of a time domain representation of a signal indicative of or representative of the reflected electromagnetic radiation waveform. The controller can determine a property of the coating based on a time offset between peaks in the waveform (e.g., an offset between a peak in a first electromagnetic radiation waveform and a peak in a second electromagnetic radiation waveform), an amplitude of one or more peaks in the waveform, or a change in the electric field (e.g., E max 、E min The properties of the coating can be determined by one or more of the presence of additional peaks in the waveform, or the transit time between peaks in the waveform. The amplitude can be evaluated or determined via a frequency domain representation of the waveform, while the electric field (e.g., E max 、E min ) can be evaluated and determined via the time domain representation of the waveform.

[0048] In one example, a controller is configured to receive an electromagnetic radiation waveform. The electromagnetic radiation waveform may include a first electromagnetic radiation waveform and a second electromagnetic radiation waveform. The controller may then be further configured to compare the first electromagnetic radiation waveform to the second electromagnetic radiation waveform. In some examples, the first electromagnetic radiation waveform is from a first scan of the component at a first time, and the second electromagnetic radiation waveform is from a second scan of the component at a second time. Determining a property of the coating may be based on at least one of: a time offset between a first peak of the first waveform and a first peak of the second waveform; a change in amplitude or electric field between a first peak of the first waveform and a first peak of the second waveform; the presence of additional peaks in the second waveform; or a transit time between a first peak of the first waveform and a second peak of the first waveform.

[0049] The time shift between peaks in the reflected electromagnetic radiation waveform indicates the level of penetration of foreign matter into the coating 112. Figure 4BAs further shown in , the time offset between peaks can refer to the time difference between the time when a peak is observed in a first electromagnetic radiation waveform (e.g., the waveform from the first scan) and the time when a peak is observed in a second electromagnetic radiation waveform (e.g., the waveform from the second scan). The first electromagnetic radiation waveform can represent the coating 112 at a first point in time, for example, when the component 102 or the coating 112 is new. The second electromagnetic radiation waveform can represent the coating 112 at a second point in time, for example, after the coating 112 has been applied or the component 102 has been installed in the engine 104. Thus, the second electromagnetic radiation waveform can represent the coating that has been exposed to foreign matter during engine operation.

[0050] It is conceivable that as the amount of foreign matter penetrating into the coating increases, the refractive index of the coating may increase. This increase in the refractive index of the coating results in an increase in the travel time of the electromagnetic radiation through the coating. That is, a pulse of electromagnetic radiation takes longer to travel through the coating. This increase in travel time changes the time at which one or more peaks in the waveform appear in the time domain representation of the waveform. Advantageously, the reflected electromagnetic radiation waveform can be analyzed to determine changes in the reflectivity of the coating, which can then be used to infer or determine the level of foreign matter penetration. In contrast, conventional methods for determining foreign matter penetration typically involve cutting the sample to determine the refractive index or the level of foreign matter penetration.

[0051] In another example, the amplitude or electric field (e.g., E max 、E min ) indicates penetration of foreign matter into the coating 112. When comparing, for example, a first peak in a first electromagnetic radiation waveform (e.g., a waveform from a first scan) and a first peak in a second electromagnetic radiation waveform (e.g., a waveform from a second scan), energy loss in the electromagnetic radiation at the coating interface is observed, i.e., the amplitude or electric field (e.g., E) in the peaks of the waveforms. max 、E min The reduction in amplitude is at least partially caused by an increase in density and / or an increase in refractive index of the coating due to penetration of foreign matter. For example, Figure 4B This reduction in electric field is shown in .

[0052] When comparing, for example, the second peak value in the first electromagnetic radiation waveform with the second peak value in the second electromagnetic radiation waveform, it is possible to observe an energy loss of the electromagnetic radiation in the coating, i.e., a decrease in the peak amplitude or electric field. The decrease in amplitude or electric field may be caused by attenuation and scattering of the electromagnetic radiation due to penetration of foreign matter. For example, Figure 4B This reduction in electric field is shown in Therefore, the ratio of the first peak to the second peak also indicates foreign matter penetration.

[0053] In another example, when comparing a first electromagnetic radiation waveform (e.g., a waveform from a first scan) to a second electromagnetic radiation waveform (e.g., a waveform from a second scan), additional peaks appear in the reflected electromagnetic waveform. The presence of additional peaks in the reflected electromagnetic waveform indicates or represents additional material interfaces on the component 102 due to a buildup or accumulation of foreign matter on the coating 112. For example, when the coating is fully penetrated, foreign matter may begin to accumulate on the surface of the coating 112, forming an additional layer of material that manifests as additional peaks in the reflected electromagnetic radiation waveform. For example, Figure 4C Additional peaks due to accumulation of foreign matter are shown.

[0054] In another example, the transit time between peaks in the waveform (e.g., the transit time between a first peak and a second peak) reflects the coating thickness. For example, in a first electromagnetic radiation waveform (e.g., the waveform from a first scan), the time between the first peak and the second peak in the time-domain representation of the waveform indicates that the coating 112 has a first thickness. In a second electromagnetic radiation waveform (e.g., the waveform from a second scan), the time between the first peak and the second peak in the time-domain representation of the waveform indicates that the coating 112 has a second thickness. In this manner, the waveform also reflects or indicates loss of the coating 112 on the component 102, for example, due to wear.

[0055] At block 165, the controller may optionally determine or assess the condition of the coating based on the properties of the coating. In some examples, the remaining life of the coating is based on the condition of the coating. In some approaches, the controller 108 in the system 100 assesses the condition of the coating 112 based on the properties of the coating 112. The condition of the coating may be, for example, the level of foreign matter penetration into the coating and / or whether foreign matter has fused or accumulated onto the coating 112. For example, the controller may determine the level of foreign matter penetration into the coating based on the properties of the coating (e.g., based on the refractive index of the coating).

[0056] In some methods, assessing the condition of the coating includes comparing the properties of the coating with data about the remaining life of the coating. Calibration data establishes or determines the level of foreign matter penetration based on the properties of a particular coating (e.g., refractive index). In one example, the calibration data includes a relationship between the condition of the coating 112 (e.g., the level of foreign matter penetration) and the properties of the coating 112 (e.g., refractive index). In this way, the controller can use the calibration data to assess the condition of the coating based on the properties of the coating. In some non-limiting examples, the condition of the coating is the level of foreign matter penetration. The level of foreign matter penetration can be a qualitative measurement, such as the percentage of the coating that has penetrated (e.g., by volume or weight), the weight of foreign matter that has penetrated into a given area of ​​the coating, and / or the depth of penetration into the coating. In other examples, the level of foreign matter penetration can be a qualitative measurement of penetration, such as high / medium / low, severe / medium / none, or the like.

[0057] At block 166, the controller determines the remaining life of the coating based on the properties. In some approaches, the controller 108 in the system 100 determines the remaining life of the coating 112 based on the properties of the coating 112. Calibration data can be used to establish or determine the remaining life of the coating 112 based on the condition of the coating (e.g., the level of foreign matter penetration or the coating thickness). Calibration data can also be used to establish or determine the remaining life of the coating 112 based on the properties of the coating (e.g., the refractive index or energy loss in the coating). In one example, the calibration data includes a relationship between the condition of the coating 112 (e.g., the level of foreign matter penetration) or the properties of the coating 112 (e.g., the refractive index) and the remaining life of the coating 112. The controller can use this calibration data to establish or determine the remaining life of the coating 112 based on the condition of the coating 112 and / or the properties of the coating 112.

[0058] As discussed above, the properties of the coating (e.g., dielectric properties) reflect or correlate with the condition of the coating (e.g., the level of foreign matter infiltration). The condition of the coating reflects or correlates with the remaining life of the coating. For example, the coating may have a certain remaining life based on the level of foreign matter infiltration, and may be determined to have no remaining life after exceeding a threshold level of foreign matter infiltration. Therefore, the controller can use the properties of the coating to determine the remaining life of the coating.

[0059] At box 168, the controller may determine an action for the engine or component based on the remaining life of the coating. The controller 108 may determine an action for the engine or component based on the remaining life of the coating. The controller 108 may also adjust the operation or maintenance of the engine based on the determined action. In some examples, the controller 108 in the system 100 conveys a command to the engine 104 based on the action. The action may be any action that maximizes or otherwise improves the remaining service life of the engine 104 and / or component 102. In some examples, the action includes reducing the rated power of the engine 104, repairing the component 102, replacing the component 102 or the coating 112, cleaning the component 102, adjusting the route of the aircraft driven by the engine, changing the payload for the engine 104, redeploying the engine 104 or the component 102 (e.g., redeploying to a less severe cycle for a degraded coating). The controller 108 may also convey a command to the engine operating system 114. For example, the controller conveys a command to the engine in response to determining that the remaining life is below a threshold.

[0060] In some methods, the controller adjusts the operation or maintenance of the engine based on the remaining life of the coating. For example, the controller adjusts the operation or maintenance of the engine. The controller can adjust the operation or maintenance of the engine to implement the action determined at box 168.

[0061] In some methods, the controller also updates the model of the engine based on the remaining life of the coating. The controller 108 can update the model of the engine based on the remaining life of the coating. In one example, when the controller 108 determines that the remaining life reflects a faster (or slower) degradation of the coating 112 as modeled by the engine model, the controller 108 adjusts the model to more closely align with the remaining life determined at block 166. In some examples, the model of the engine 104 is stored in the memory device 122. In other examples, the model is stored in a memory or other external data system in communication with the controller 108.

[0062] In some methods, the controller causes the message or alert to be displayed via a user interface device associated with the engine. In some examples, the controller 108 causes the message or alert to be displayed via a user interface device 116 associated with the engine 104. The user interface device 116 can be an audio, visual, virtual, augmented, or mixed reality device including one or more displays. In some examples, the message or alert reminds a user of the engine 104 whether the engine 104 or the component 102 is suitable for continued service or operation. In some examples, the message or alert indicates that the engine 104 or the component 102 should be redeployed, repaired, or refurbished. In one example, the message or alert reminds a user who is working on the engine (e.g., at an overhaul or repair shop) to pay attention to a specific work range, wherein the user is to go to a specific section of the engine and perform a task for the component 102.

[0063] In some methods, the action determined at block 168 is to change or replace the coating. For example, the coating 112 can be customized based on the remaining life. In one example, the controller 108 communicates with a coating or repair device that adjusts the coating of the component 102 based on the remaining life. In this way, the system 100 can customize the coating of the component 102 based on the specific needs of the component 102 determined via inspection.

[0064] Figure 4A 、 4B and 4C include exemplary reflected electromagnetic waveforms. Figure 4A 、 4B and 4C show a time domain representation of the reflected electromagnetic radiation waveform.

[0065] Figure 4A A graph showing a first electromagnetic radiation waveform 170 is included. The first electromagnetic radiation waveform 170 is reflected from an original sample. The graph depicts the change in the electric field of the electromagnetic radiation signal over time (in picoseconds (ps)). The original sample is a sample from a component having a thermal barrier coating (TBC) that is not exposed to external conditions, such as foreign matter or engine operating conditions. The original sample has no CMAS infiltration or deposits. The component is made of aluminum oxide (Al2O3). The first electromagnetic radiation waveform 170 includes a first peak 172 and a second peak 174. The first peak 172 originates from the interface between the air and the thermal barrier coating. The second peak 174 originates from the interface between the thermal barrier coating and the component.

[0066] Figure 4B A graph showing a first electromagnetic radiation waveform 170 and a second electromagnetic radiation waveform 180 inserted on the same graph is included. The graph depicts the change in the electric field of the electromagnetic radiation signal over time (in picoseconds (ps)). The second electromagnetic radiation waveform 180 is reflected from a second sample. The second sample is from a 1 cubic centimeter (cm3) of thermal barrier coating. 2 ) area of ​​the component. In the second sample, the CMAS penetrated into the thermal barrier coating, and no CMAS was deposited on top of the thermal barrier coating. The second electromagnetic radiation waveform 180 includes a first peak 182 and a second peak 184. The first peak 182 originates from the interface between the air and the thermal barrier coating. The first peak 182 shows the maximum energy (E) from the time domain representation of the waveform. max The second peak 184 originates from the interface between the thermal barrier coating and the component. The second peak 184 shows the minimum energy (E) from the time domain representation of the waveform. min ).

[0067] The second electromagnetic radiation waveform 180 is similar to the first electromagnetic radiation waveform 170, but the second peak 184 of the second electromagnetic radiation waveform 180 is offset in time from the second peak 174 of the second electromagnetic radiation waveform 180. The time offset between the second peak 184 and the second peak 174 is at least partially due to the penetration of the CMAS into the thermal barrier coating. The transmission time between the first peak 182 (e.g., the air-thermal barrier coating interface) and the second peak 184 (e.g., the thermal barrier coating-component interface) in the infiltrated sample is also longer than the transmission time between the first peak 172 (e.g., the air-thermal barrier coating interface) and the second peak 174 (e.g., the thermal barrier coating-component interface) in the original sample. In addition, the electric field (E) of the second peak 184 from the infiltrated sample is greater than that of the second peak 184. min ) is less than the electric field (E min Similarly, the electric field (E max ) is less than the electric field (E max ). The amplitude may also be determined via a power spectrum obtained from a Fast Fourier Transform (FFT) to convert the time domain representation of the first electromagnetic radiation waveform 170 and the second electromagnetic radiation waveform 180 into a frequency domain representation.

[0068] The change in the electric field (or amplitude in the frequency domain) in the time domain reflects the energy loss of electromagnetic radiation when passing through the thermal barrier coating. The energy loss is at least partially due to the penetration of CMAS in the thermal barrier coating, which, as discussed above, causes the density or refractive index of the coating to increase. The electric field (E) of the first peak 182 is max ) and the electric field of the first peak 172 (E max ) reflects the level of foreign matter penetration. Similarly, the electric field of the second peak 184 (E min ) and the electric field of the second peak 174 (E min The ratio of the CMAS to the peaks in the time domain representation of the waveform and the change in the electric field between the infiltrated and pristine samples is at least partially due to the increased refractive index and increased absorption or scattering due to the infiltration of the CMAS.

[0069] Figure 4C A graph showing a first electromagnetic radiation waveform 170 and a third waveform 190 inserted on the same graph is included. The graph depicts the change in the electric field (time domain representation) of the electromagnetic radiation signal over time (in picoseconds (ps)). The third waveform is reflected from a third sample. The third sample is a sample from a component having a 1 cubic centimeter (cm3) thermal barrier coating. 2). In the third sample, CMAS penetrated into the thermal barrier coating, and a CMAS layer was also deposited on top of the thermal barrier coating. A third waveform 190 includes a first peak 192, a second peak 194, and a third peak 196. First peak 192 originates from the interface between air and the CMAS layer. Second peak 194 originates from the interface between the thermal barrier coating and the component. Third peak 196 originates from the interface between the CMAS and the thermal barrier coating.

[0070] Third waveform 190 is similar to first electromagnetic radiation waveform 170, except that second peak 194 of third waveform 190 is offset in time from second peak 174 of first electromagnetic radiation waveform 170. The temporal offset between second peak 194 and second peak 174 is at least partially due to the penetration of CMAS into the thermal barrier coating, which increases the density and refractive index of the thermal barrier coating. Furthermore, third waveform 190 includes third peak 196, which is due to the presence of a CMAS deposit on the thermal barrier coating. The CMAS deposit on the thermal barrier coating also causes the electromagnetic radiation to reach the detector of the electromagnetic inspection device more quickly than if the thermal barrier coating were not deposited with CMAS.

[0071] Figure 5 is a graph showing the transmission time (in picoseconds (ps)) of electromagnetic radiation through a coating as a function of the percentage of CMAS penetration into the coating. The coating may be, for example, a protective coating, such as a thermal barrier coating. It is contemplated that the transmission time through the coating may increase as CMAS penetration increases due to changes in the refractive index of the thermal barrier coating caused by penetration. As shown, the transmission time is correlated with the percentage of CMAS penetration, such that the level of CMAS penetration in a sample can be estimated or predicted based on the transmission time of electromagnetic radiation reflected from the sample. The remaining life of a thermal barrier coating may also be correlated with the percentage of CMAS penetration. Effective medium theory or approximations may be used to calculate properties of a coating, such as the refractive index of a coating, where CMAS penetrates into the coating. In some methods, effective medium theory is used to determine effective properties, such as the refractive index, of a composite material (e.g., a first or bulk material infiltrated by a second material) based on the properties of the bulk material and the second or infiltrating material. Any suitable effective medium theory may be used.

[0072] Figure 5 The graph shows that for a given coating thickness, the transmission time increases with the percentage of foreign matter that has penetrated into the coating. Figure 5The coating thickness of the graph is about 160 micrometers (μm). Two known samples were analyzed to generate the graph. The first sample included a thermal barrier coating that was fully infiltrated with CMAS (100% penetration). The second sample was the original sample that was not infiltrated with CMAS (0% penetration). The percent penetration at the midpoint was calculated to determine the resolution of the method described herein, i.e., the lowest level of CMAS penetration that can be detected using such a method. It was determined that for a coating thickness of about 160 micrometers (μm), about 7% penetration could be detected. Figure 5 In the graph, 7% penetration represents the distance, or step size, between points on the x-axis.

[0073] Figure 6 is a graph showing the minimum CMAS penetration detectable using the method described herein. This graph shows the minimum percentage of CMAS penetration detectable using the method described herein as a function of coating thickness. Figure 6 In , the minimum detectable change in CMAS penetration was determined for coating thicknesses ranging from about 50 micrometers (μm) to about 1100 micrometers (μm). Figure 6 As shown, the minimum percentage of CMAS penetration into a coating that can be detected using the methods described herein may vary with the thickness of the coating. Smaller changes in CMAS penetration can be detected in thicker coatings.

[0074] The terms and expressions used herein have their ordinary technical meanings as assigned by those skilled in the art to such terms and expressions, unless otherwise specified herein. Unless otherwise expressly stated, the word "or" as used herein should be interpreted as having a disjunctive rather than a conjunctive construction. Unless otherwise specified herein, the terms "coupled," "fixed," "attached to," and the like refer to both direct coupling, fixing, or attachment and indirect coupling, fixing, or attachment through one or more intermediate components or features.

[0075] The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0076] As used herein throughout the specification and claims, approximating language is used to modify any quantitative representation that can be permissibly varied without resulting in a change in the basic function to which it is related. Thus, a value modified by one or more terms such as "about," "approximately," and "substantially" is not limited to the precise value specified. In at least some cases, approximating language may correspond to the precision of an instrument used to measure the value, or the precision of a method or machine used to construct or manufacture a component and / or system. For example, approximating language may mean within a 10% margin.

[0077] The use of singular terms such as "a," "an," and the like is intended to encompass both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms "including," "having," "comprising," and "containing" are to be construed as open-ended terms. The phrase "at least one of" as used herein is to be construed in a disjunctive sense. For example, the phrase "at least one of A and B" is intended to encompass A, B, or both A and B. Similarly, the word "or" as used herein is to be construed as having a disjunctive rather than a conjunctive construction, unless expressly indicated otherwise.

[0078] Further aspects of the present disclosure are provided by the subject matter of the following clauses:

[0079] A system comprises: an electromagnetic inspection device, the electromagnetic inspection device comprising: an electromagnetic radiation source, the electromagnetic radiation source being used to generate pulsed electromagnetic radiation that penetrates a coating of a component of an engine; and a detector, the detector being used to receive reflected electromagnetic radiation reflected from the component; and a controller, the controller being in operative communication with the electromagnetic inspection device, the controller being configured to: receive an electromagnetic radiation waveform representing the reflected electromagnetic radiation; determine a property of the coating based on the electromagnetic radiation waveform; determine a remaining life of the coating based on the property; and update a model of the engine based on the remaining life of the coating.

[0080] A system as in any preceding clause, wherein the electromagnetic radiation source is configured to generate pulsed electromagnetic radiation in the terahertz frequency range.

[0081] The system of any preceding clause, wherein the coating is a thermal barrier coating.

[0082] The system of any preceding clause, wherein the controller is further configured to assess a condition of the coating based on the property of the coating, wherein the remaining life of the coating is based on the condition of the coating.

[0083] The system of any preceding clause, wherein the controller is further configured to determine the remaining life based on calibration data, the calibration data comprising a relationship between the condition of the coating and the remaining life of the coating.

[0084] A system as claimed in any preceding clause, wherein the condition of the coating is the level of penetration of foreign matter into the coating.

[0085] A system according to any preceding clause, wherein the electromagnetic radiation waveform includes a first electromagnetic radiation waveform and a second electromagnetic radiation waveform, and wherein the controller determines the property of the coating based on at least one of: a time offset between a first peak of the first electromagnetic radiation waveform and a first peak of the second electromagnetic radiation waveform; a change in amplitude or electric field between the first peak of the first electromagnetic radiation waveform and the first peak of the second electromagnetic radiation waveform; the presence of additional peaks in the second electromagnetic radiation waveform; or a transmission time between the first peak of the first electromagnetic radiation waveform and the second peak of the first electromagnetic radiation waveform.

[0086] The system of any preceding clause, wherein the first electromagnetic radiation waveform is from a first scan of the component at a first time, and the second electromagnetic radiation waveform is from a second scan of the component at a second time.

[0087] A system as in any preceding clause, wherein the property is a dielectric property of the coating or material loss from the coating.

[0088] The system of any preceding clause, wherein the controller is configured to determine the remaining life of the coating based on calibration data, the calibration data comprising a relationship between the property of the coating and the remaining life of the coating.

[0089] The system of any preceding clause, wherein the controller is configured to compare the remaining life of the coating to a threshold, wherein upon determining that the remaining life of the coating is below the threshold, the controller determines an action for the engine.

[0090] A method comprises: at an electromagnetic radiation source, directing pulsed electromagnetic radiation through a coating of a component of an engine; at a detector, receiving reflected electromagnetic radiation reflected from at least one of the coating or the component; determining a property of the coating based on the reflected electromagnetic radiation; determining a remaining life of the coating based on the property; and adjusting operation or maintenance of the engine based on the remaining life.

[0091] A method as in any preceding clause, wherein the electromagnetic radiation source generates pulsed electromagnetic radiation in the terahertz frequency range.

[0092] A method as defined in any preceding clause, wherein the coating is a thermal barrier coating.

[0093] A method as in any preceding clause wherein the property is a dielectric property of the coating or material loss from the coating.

[0094] A method as in any preceding clause, further comprising determining a condition of the coating based on the property.

[0095] A method as in any preceding clause wherein the condition is the level of penetration of foreign matter into the coating.

[0096] The method according to any of the preceding clauses further includes: receiving a reflected electromagnetic waveform indicative of the reflected electromagnetic radiation, the reflected electromagnetic waveform comprising a first electromagnetic radiation waveform and a second electromagnetic radiation waveform, wherein determining the property of the coating is based on at least one of: a time offset between a first peak of the first electromagnetic radiation waveform and a first peak of the second electromagnetic radiation waveform; a change in amplitude or electric field between the first peak of the first electromagnetic radiation waveform and the first peak of the second electromagnetic radiation waveform; the presence of additional peaks in the second electromagnetic radiation waveform; or a transmission time between the first peak of the first electromagnetic radiation waveform and the second peak of the first electromagnetic radiation waveform; and comparing the first electromagnetic radiation waveform with the second electromagnetic radiation waveform, wherein the first electromagnetic radiation waveform is from a first scan of the component at a first time and the second electromagnetic radiation waveform is from a second scan of the component at a second time.

[0097] A non-transitory computer-readable storage medium comprising instructions that, when executed, cause a processor of a controller to: receive an electromagnetic radiation waveform reflected from a coating of a component of an engine, or from at least one of the components; determine a property of the coating based on the electromagnetic radiation waveform; determine a remaining life of the coating based on the property; and update a model of the engine based on the remaining life.

[0098] A non-transitory computer-readable storage medium according to any of the preceding clauses, wherein the controller is further configured to: determine a condition of the coating based on the property, wherein the remaining life of the coating is based on the condition of the coating; and determine the remaining life based on calibration data, wherein the calibration data includes a relationship between the condition of the coating and the remaining life of the coating.

Claims

1. A system, characterized in that: include: An electromagnetic inspection device, comprising: an electromagnetic radiation source for generating pulsed electromagnetic radiation that penetrates a coating of a component of the engine; and a detector for receiving reflected electromagnetic radiation reflected from the component; and a controller in operable communication with the electromagnetic inspection device, the controller being configured to: receiving an electromagnetic radiation waveform representative of the reflected electromagnetic radiation; determining a property of the coating based on the electromagnetic radiation waveform; determining a remaining life of the coating based on the property; and A model of the engine is updated based on the remaining life of the coating.

2. The system according to claim 1, wherein: The electromagnetic radiation source is used to generate pulsed electromagnetic radiation in the terahertz frequency range.

3. The system according to claim 1, wherein: Wherein the coating is a thermal barrier coating.

4. The system according to claim 1, wherein: Wherein the controller is further configured to assess a condition of the coating based on the property of the coating, wherein the remaining life of the coating is based on the condition of the coating.

5. The system according to claim 4, characterized in that Wherein the controller is further configured to determine the remaining life based on calibration data, the calibration data comprising a relationship between the condition of the coating and the remaining life of the coating.

6. The system according to claim 4, characterized in that The condition of the coating is the level of penetration of foreign matter into the coating.

7. The system according to claim 1, wherein: wherein the electromagnetic radiation waveform comprises a first electromagnetic radiation waveform and a second electromagnetic radiation waveform, and wherein the controller determines the property of the coating based on at least one of: a time offset between a first peak of the first electromagnetic radiation waveform and a first peak of the second electromagnetic radiation waveform; a change in amplitude or electric field between the first peak of the first electromagnetic radiation waveform and the first peak of the second electromagnetic radiation waveform; the presence of additional peaks in the second electromagnetic radiation waveform; or a transit time between the first peak of the first electromagnetic radiation waveform and the second peak of the first electromagnetic radiation waveform.

8. The system according to claim 7, characterized in that The first electromagnetic radiation waveform is from a first scan of the component at a first time, and the second electromagnetic radiation waveform is from a second scan of the component at a second time.

9. The system according to claim 1, wherein: wherein the property is a dielectric property of the coating or a loss of material from the coating.

10. The system according to claim 1, wherein: Wherein the controller is configured to determine the remaining life of the coating based on calibration data, the calibration data comprising a relationship between the property of the coating and the remaining life of the coating.

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