Transparent Ceramic Coating Cohesion Loss Detection
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Solution Overview
Problem
Existing methods for non-destructive inspection of transparent ceramic thermal barrier layers on substrates face challenges in accurately observing and measuring cohesion losses due to poor contrast between separation spots and the underlying layer, making it difficult to determine the extent of adhesion failures in coatings used for high-pressure turbine components.
Innovation Solution
Observing images of the ceramic layer at wavelengths longer than or equal to 500 nm enhances contrast between separation and non-separation zones, allowing for reliable detection and measurement of cohesion losses, which can be achieved through narrow spectrum lighting or using a camera with filters adjusted to these specific wavelengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If optical observation is performed at visible wavelengths to detect separation spots, then the inspection can be conducted with standard optical equipment, but the contrast between separation spots and underlying layer is poor making accurate measurement difficult
Solution Approach 1:
The patent changes the observation wavelength parameter from standard visible light to infrared wavelengths (≥500 nm). This parameter change exploits the different optical absorption characteristics of the ceramic layer and underlying structures at infrared wavelengths, creating enhanced contrast between separation spots and non-separation areas without requiring complex equipment modifications
Solution Approach 2:
The patent introduces an optical filter as an intermediary component that selectively transmits infrared wavelengths (≥500 nm) while blocking shorter wavelengths. This filter acts as a mediator between the light source and the observation system, enabling wavelength-specific observation that enhances spot visibility and measurement accuracy
2Productivity
If standard visible light observation is used to detect cohesion losses, then the method remains simple and quick, but short wavelength noise prevents reliable distinction between separated and non-separated zones
Solution Approach 1:
The patent modifies the observation wavelength parameter to infrared (≥500 nm), which eliminates short wavelength noise while maintaining the simplicity and speed of optical observation. This parameter change allows reliable distinction between separation and non-separation zones through enhanced contrast in the infrared spectrum
Solution Approach 2:
The patent extracts and eliminates the harmful short wavelength noise component from the observation spectrum by using infrared wavelengths (≥500 nm). This selective extraction of the useful wavelength range removes the noise that previously prevented reliable detection, while maintaining the quick inspection capability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly improves the visibility and measurement accuracy of cohesion losses, enabling effective non-destructive assessment of adhesion in ceramic coatings by eliminating short wavelength noise and increasing contrast between separation and non-separation zones.
Implementation Method 1
the ceramic layer being transparent, it leaves visible the underlayer
Implementation Method 2
observing the image at wavelengths longer than or equal to 500 nm makes it possible to eliminate short wavelength noise
Data Source
AI summary
A method of determining the appearance of losses of cohesion in a transparent ceramic coating layer (16) formed on a substrate (10), the method comprising the steps that consist firstly in looking for an image representative of a separation zone, if any, between the ceramic layer and the substrate, and secondly in analyzing the detected image, if any, with the image being viewed optically at particular wavelengths that are greater than or equal to 500 nm.