Terahertz Electromagnetic Inspection for Engine Coating Life

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Solution Overview

Problem

Protective coatings on components, such as those in aircraft turbine engines, are susceptible to infiltration by foreign materials like CMAS, which degrades the coatings and compromises the underlying components, necessitating costly and time-consuming destructive testing for assessment.

Innovation Solution

An electromagnetic inspection system using pulsed terahertz radiation to non-destructively evaluate coating condition and foreign material infiltration by analyzing reflected electromagnetic radiation waveforms, determining properties like refractive index and coating thickness to assess remaining life and condition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If destructive testing is used to assess coating condition, then measurement precision is improved, but productivity deteriorates and loss of time increases

Engineering Contradiction:

Improvecoating condition assessment accuracyVSAvoidinspection throughput

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent replaces destructive mechanical testing methods with non-destructive electromagnetic inspection using terahertz radiation. The electromagnetic radiation penetrates the coating and reflects off the substrate, allowing assessment of coating integrity, thickness, and foreign material infiltration without physically damaging the component. This substitution maintains measurement precision while eliminating the need to scrap inspected components, thereby improving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If destructive testing is used to assess coating condition, then measurement precision is improved, but loss of time increases

Engineering Contradiction:

Improvecoating condition assessment accuracyVSAvoidinspection time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The electromagnetic inspection system performs rapid non-destructive assessment by directing terahertz radiation at the coating and analyzing reflected signals. This eliminates the time-consuming destructive testing process where components must be removed, tested, and then discarded. The inspection can be performed quickly in-situ, significantly reducing loss of time while maintaining accurate measurement of coating condition.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If non-destructive testing is used, then productivity is improved and loss of time is reduced, but measurement precision deteriorates

Engineering Contradiction:

Improveinspection throughputVSAvoidcoating condition assessment accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent employs terahertz electromagnetic radiation which has unique penetration and reflection characteristics that provide high-precision measurements. The radiation penetrates the coating material and reflects off the coating-substrate interface and any foreign materials, allowing accurate determination of coating thickness, integrity, and infiltration levels. This electromagnetic approach achieves measurement precision comparable to or exceeding destructive methods while enabling non-destructive inspection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system utilizes the specific electromagnetic parameters of terahertz radiation (frequency, wavelength, penetration depth) that are optimized for interacting with coating materials. By selecting and tuning the electromagnetic parameters, the system achieves high measurement precision for coating thickness and foreign material detection while maintaining non-destructive operation, thus resolving the contradiction between precision and productivity.

Inventive Principle:

Principle #35Parameter changes

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 evaluation of coating integrity, reducing costs and time by allowing components to be returned to service, and providing real-time data for maintenance decisions.

Implementation Method 1

an electromagnetic radiation source to generate pulsed electromagnetic radiation that penetrates through a coating of a component of an engine

Methodology Applied

Scientific EffectElectromagnetic radiation generation: Electromagnetic Induction

Implementation Method 2

a detector to receive reflected electromagnetic radiation that is reflected from the component

Methodology Applied

Scientific EffectElectromagnetic reflection: Reflection

Data Source

PatentUS20250290859A1Electromagnetic inspection systems and methods

Publication Date: 2025.09.18 GENERAL ELECTRIC CO

AI summary

In some embodiments, a system for evaluation a coating, such as a thermal barrier coating, includes an electromagnetic inspection device and a controller in operative communication with the electromagnetic inspection device. The electromagnetic inspection device includes an electromagnetic radiation source and a detector. The electromagnetic radiation source generates pulsed electromagnetic radiation that penetrates through a coating of a component of an engine. The detector receives reflected electromagnetic radiation that is reflected from the component. The controller is configured to receive electromagnetic radiation waveform that is representative of the reflected electromagnetic radiation. The controller is also configured to determine a property of the coating based on the electromagnetic radiation waveform and to determine a remaining life of the coating based on the property. The controller may also be configured to communicate a control command to the engine based on the remaining life.