Coating Analysis System for Turbine Bond Quality
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Solution Overview
Problem
Current techniques for inspecting coatings on components in harsh environments lack the resolution and sensitivity to detect smaller defects and delamination, particularly around cooling holes in turbine blades, leading to potential thermal damage and reduced component lifespan.
Innovation Solution
A coating analysis system that uses inductive heating and infrared radiation emission measurements to assess the tensile bond strength between the coating and the underlying component, differentiating between well-bonded and poorly bonded areas through rate of IR emission, enabling non-destructive evaluation of bond quality and delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection techniques are used to examine coatings, then the inspection method is simple and quick, but the resolution and sensitivity are insufficient to detect smaller defects and delamination
Solution Approach 1:
The patent replaces visual inspection (mechanical/optical system) with eddy current measurement and flash infrared detection (electromagnetic field-based systems). This substitution enables detection of smaller defects and delamination by utilizing electromagnetic interactions with the coating and substrate, achieving higher measurement precision without significantly increasing operational complexity
Solution Approach 2:
The patent changes the measurement parameter from visual observation to electrical properties (eddy currents) and thermal properties (infrared radiation). By measuring electrical conductivity changes and thermal emission patterns, the system can detect subsurface delamination and coating defects that are invisible to the naked eye, thereby improving detection resolution
2Measurement precision
If eddy current measurement or flash infrared detection is used to examine coatings, then the detection sensitivity improves, but the resolution and sensitivity for finding smaller defects are still insufficient
Solution Approach 1:
The patent merges eddy current measurement and flash infrared detection into a single integrated inspection system. The eddy current component detects electrical property changes indicating delamination, while the infrared component detects thermal emission patterns. By combining these two complementary techniques, the system achieves both high sensitivity for small defects and high reliability through multiple detection mechanisms
Solution Approach 2:
The system uses feedback from both eddy current and infrared measurements to improve detection reliability. The eddy current data provides information about coating integrity, while infrared thermal patterns provide complementary information about bond quality. The combined feedback allows the system to distinguish between actual defects and measurement variations, enhancing both sensitivity and reliability
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 method provides a non-destructive means to accurately measure tensile bond strengths, allowing for the identification of weaker bonds, estimation of remaining useful life, and scheduling of maintenance or restoration, thereby extending component lifespan and ensuring safe operation.
Implementation Method 1
a heating system configured to inductively heat a component having a coating
Implementation Method 2
an inspection system configured to measure a rate of radiation emission from the component and the coating from inductively heating the component
Data Source
AI summary
A coating analysis system and method inductively heat a component having a coating. Optionally, the component is heated while a cooling fluid flows through cooling holes extending through the component and the coating. The system and method measure rates of infrared radiation emission from the component and the coating at different locations on the component and the coating. The system and method determining bond qualities (e.g., tensile strengths of bonds) between the coating and the component at the different locations based on the rates of infrared radiation emission that are measured.