Coating Thickness Prediction via Spray Spot Volume
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Solution Overview
Problem
Current methods for determining the thickness of thermal barrier coatings on gas turbine components are time-consuming and material-intensive, requiring complete coatings on test substrates, or rely on complex software simulations.
Innovation Solution
A method that calculates the thickness of a coating by determining the volume of a spray spot using profilometry or 3-D scanning, allowing for the prediction of layer thickness based on the equation hlayer=1/(v*p)*ΔVspot/Δt, where v is the device speed, p is the track offset, and ΔVspot is the volume of the spray spot produced in a fixed time Δt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complete coatings are applied to test substrates to determine coating thickness, then measurement precision is improved, but loss of substance and loss of time worsen
Solution Approach 1:
The patent segments the coating determination process by measuring only a single spray spot instead of applying complete coatings. The spray spot volume is measured and used to calculate the coating thickness for the entire component, dividing the measurement task into a manageable, material-efficient unit while maintaining measurement precision through proper sampling and calculation methods.
2Measurement precision
If complete coatings are applied to test substrates to determine coating thickness, then measurement precision is improved, but loss of time worsens
Solution Approach 1:
The patent performs preliminary measurement on a single spray spot before applying complete coatings to production components. By determining the coating thickness characteristics from a representative spray spot measurement, the method eliminates the need for time-consuming complete coating applications and subsequent measurements, significantly reducing testing time while maintaining measurement precision.
3Loss of substance
If simulation methods are used to determine coating thickness, then loss of substance and loss of time are reduced, but device complexity worsens
Solution Approach 1:
The patent replaces complex simulation software with a straightforward mathematical calculation based on physical measurement. Instead of using resource-intensive computational models, the method uses a simple equation that relates spray spot volume to coating thickness, substituting mechanical/computational complexity with direct physical measurement and basic calculation.
4Loss of substance
If spray spot volume measurement is used to determine coating thickness, then loss of substance and loss of time are reduced, but measurement precision may worsen
Solution Approach 1:
The patent incorporates feedback by using the measured spray spot volume to calculate and control the coating thickness. The measurement results are fed back into the coating process through the thickness calculation equation, allowing for precise control and adjustment of coating parameters to achieve the desired thickness while minimizing material usage and testing time.
Data Source
AI summary
A method for predetermining a thickness of a coating which is to be arranged on a substrate is provided. A spray spot is arranged on a surface of the substrate or a test substrate. The volume of the spray spot is determined, and based on the determined volume, the thickness of a layer which is to be applied is worked out. An arrangement for predetermining the thickness of a coating is further provided.