Infrared Detection for Multilayer Coating Subsurface Defect Mapping
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Solution Overview
Problem
Current inspection methods for subsurface defects in thermal barrier coatings of gas turbine components are destructive, costly, and time-consuming, necessitating a non-destructive method to assess usability risk and determine the size and location of defects.
Innovation Solution
A system utilizing an infrared detection device and processing unit to capture and analyze infrared images, generating subsurface defect maps and risk maps to identify areas of high, medium, and low risk, allowing for the comparison of defect risk levels to allowable inspection limits without removing the coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal barrier coating is stripped and replaced after predetermined inspection cycles, then component reliability is maintained, but inspection time and cost increase significantly
Solution Approach 1:
The patent replaces mechanical/destructive inspection methods with infrared thermal imaging technology. The infrared detection device uses thermal radiation detection to identify subsurface defects without mechanical contact or coating removal, thereby maintaining reliability while dramatically reducing inspection time and eliminating the need for destructive stripping and replacement operations
Solution Approach 2:
The patent introduces infrared radiation as an intermediary to detect subsurface defects. By applying a thermal stimulus and detecting the infrared radiation patterns that emerge, the system can identify delamination and defects without directly contacting or damaging the coating, thus maintaining reliability while avoiding time-consuming destructive inspection
2Measurement precision
If thermal barrier coating is stripped and replaced, then subsurface defects are detected, but coating material is lost and reapplication cost increases
Solution Approach 1:
The patent substitutes mechanical removal methods with non-contact infrared detection. The infrared detection device penetrates the coating visually through thermal imaging, allowing precise defect detection without removing any coating material, thus eliminating material loss while maintaining high detection accuracy
Solution Approach 2:
The patent creates a thermal image copy or map of the coating's subsurface structure. By generating infrared images that reveal defect locations and characteristics, the system provides accurate defect information without physically removing the coating, thereby preventing material loss while achieving precise measurement
3Temperature
If multiple layers of thermal barrier coating are applied, then thermal insulation performance is improved, but complexity of inspection for subsurface defects increases
Solution Approach 1:
The infrared detection device performs multiple functions simultaneously: it detects subsurface defects, generates thermal images, creates defect maps, and provides risk assessment all through a single non-destructive inspection process. This universal approach handles the complexity of multilayer inspection without requiring separate procedures for each layer or defect type
Solution Approach 2:
The patent replaces complex mechanical inspection procedures with infrared thermal imaging technology. The infrared detection device penetrates multiple coating layers using thermal radiation detection, automatically generating comprehensive defect information without the manual complexity of layer-by-layer inspection or destructive testing
4Ease of manufacture
If non-destructive inspection method is used, then coating can be preserved and reinspection is possible, but current non-destructive methods have limitations in detecting subsurface defects
Solution Approach 1:
The patent changes the inspection parameters by using infrared thermal radiation detection instead of conventional visual or tactile methods. By applying thermal stimulus and detecting infrared radiation patterns, the system achieves precise subsurface defect detection while preserving the coating, overcoming the limitations of previous non-destructive methods
Solution Approach 2:
The patent uses infrared radiation as an intermediary to bridge the gap between non-destructive inspection and subsurface defect detection. The infrared detection device detects thermal patterns that reveal subsurface conditions, providing precise defect information while maintaining coating integrity, thus resolving the limitation of conventional non-destructive methods
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
Enables non-destructive assessment of subsurface defects, reducing inspection time and costs by providing a graphical display of defect locations and risk levels, facilitating informed decisions on the continued use of thermal barrier coatings.
Implementation Method 1
an infrared detection device for capturing infrared images of the multilayered coating
Data Source
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AI summary
A system for qualifying usability risk associated with subsurface defects (20) in a multilayer coating (10) includes a component (14) having a multilayer coating (10), an infrared detection device (102) for capturing infrared images (104) of the multilayered coating (10) and a processing unit (106) that is in electronic communication with the infrared detection device (102) where the processing unit (106) generates a subsurface defect map (116) of the multilayer coating (10) based on the infrared images (104). The system further includes a risk map of the component (14).