Optical Coating Thickness Measurement via Digital Surface Mapping
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Solution Overview
Problem
Current methods for measuring coating thickness on turbine engine parts require destructive cross-sectioning and microscopy, making them costly and time-consuming.
Innovation Solution
An optical measuring system that projects a light pattern on a surface, captures reflections with multiple imaging devices, and compares data maps to determine coating thickness without physically altering the part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If cross-sectioning and microscopy are used to measure coating thickness, then measurement precision is improved, but the part is destroyed and inspection becomes expensive and time-consuming
Solution Approach 1:
The patent creates a digital copy (data map) of the surface geometry through optical scanning. By scanning the surface before and after coating, the system captures the geometric changes without physical contact or destruction of the part. This digital copying approach allows repeated measurements and eliminates the need for destructive cross-sectioning while maintaining measurement accuracy.
Solution Approach 2:
The patent replaces the mechanical destruction method (cross-sectioning with microscopy) with an optical measurement system. The optical scanner uses light to capture surface geometry, eliminating the need for physical cutting and microscopic examination. This substitution maintains measurement precision while avoiding part destruction and reducing inspection time.
2Measurement precision
If cross-sectioning is performed to measure coating thickness, then measurement accuracy is improved, but the part is destroyed
Solution Approach 1:
The system creates a digital geometric copy of the surface through optical scanning. By capturing the surface profile before and after coating application, the system measures coating thickness through geometric comparison of the digital models rather than physical cross-sectioning. This eliminates part destruction while maintaining measurement accuracy.
Solution Approach 2:
The patent replaces the mechanical cross-sectioning process with an optical scanning system. The optical method captures surface geometry through reflected light patterns, eliminating the need for physical cutting and sample preparation. This substitution achieves the same measurement goal without harmful mechanical action on the part.
3Measurement precision
If traditional microscopy methods are used, then coating thickness can be measured, but the process is time-consuming
Solution Approach 1:
The system rapidly captures digital copies of the surface geometry through optical scanning. By creating complete data maps of the surface before and after coating, the system can quickly compare the geometric changes to determine coating thickness. This digital copying approach is much faster than traditional microscopy while maintaining measurement precision.
Solution Approach 2:
The patent replaces time-consuming microscopy with rapid optical scanning. The optical system captures surface geometry through reflected light patterns, enabling quick acquisition of complete surface data. This substitution dramatically reduces inspection time while maintaining or improving measurement precision through digital data processing.
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, efficient measurement of coating thickness, reducing costs and time while allowing for faster inspection of multiple parts.
Implementation Method 1
projecting a pattern of light on a surface
Implementation Method 2
A first reflection of the pattern of light is received at a first imaging capturing device while a second reflection of the pattern of light is received by the same image capturing device at a different location
Data Source
AI summary
A method of measuring a coating thickness involves projecting a pattern of light on a surface. A first reflection of the pattern of light is received by a first image capturing device. A second reflection of the pattern of light is received by an image capturing device which may be the same or a different image capturing device. The first reflection is compared with the second reflection. A first dated map of the surface is created by comparing the first reflection and the second reflection. A coating is deposited on the surface. A second data map of the surface with the coating is created by comparing reflections. The first data map and the second data map are then compared to determine a thickness of the coating.