Thermal barrier coating spallation detection system

• US 10,641,720 B2
• Filed: 10/06/2017
• Issued: 05/05/2020
• Est. Priority Date: 10/06/2017
• Status: Active Grant

• Current Assignee: GE Infrastructure Technology, LLC (GE Vernova, Inc.)
• Original Assignee: General Electric Company
• Inventors: Ellis, Andrew David, Schleif, Kurt Kramer, Snider, Zachary John
• Primary Examiner(s): Porta, David P
• Assistant Examiner(s): Sahu, Meenakshi S
• Application Number:
  US15/726,759
• Publication Number:
  US 20190107499A1
• Time in Patent Office: 942 Days
• Field of Search: 2504591
• CPC Class Codes: C23C 28/3455 with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
• CPC Class Codes: C23C 4/067 containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
• CPC Class Codes: C23C 4/073 containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
• CPC Class Codes: F01D 5/288 Protective coatings for blades
• CPC Class Codes: G01N 21/8422 Investigating thin films, e.g. matrix isolation method
• CPC Class Codes: G01N 25/72 Investigating presence of flaws

Abstract

The present application thus provides a thermal barrier coating spallation detection system for a gas turbine. The thermal barrier coating spallation detection system may include a hot gas path component with a phosphor layer and a thermal barrier coating, a stimulant radiation source, and an optical device such that the optical device directs stimulant radiation at the thermal barrier coating and receives emission radiation. A change in the received emission radiation indicates spallation of the thermal barrier coating.

Claims

1. A thermal barrier coating spallation detection system for a gas turbine engine, comprising:

a hot gas path component installed within the gas turbine;

the hot gas path component comprising a phosphor layer and a thermal barrier coating applied over the phosphor layer;

a stimulant radiation source; and

an optical device;

wherein the optical device directs stimulant radiation at the thermal barrier coating and receives emission radiation; and

wherein a change in the received emission radiation caused by fluorescence of the phosphor layer indicates spallation of the thermal barrier coating.

2. The thermal barrier coating spallation detection system of claim 1, wherein the stimulant radiation source comprises a laser.

3. The thermal barrier coating spallation detection system of claim 1, further comprising an optical filter in communication with the optical device.

4. The thermal barrier coating spallation detection system of claim 1, further comprising a digital camera in communication with the optical device.

5. The thermal barrier coating spallation detection system of claim 4, wherein the digital camera comprises a pixel grid.

6. The thermal barrier coating spallation detection system of claim 5, wherein a change in the pixel grid indicates spallation of the thermal barrier coating.

7. The thermal barrier coating spallation detection system of claim 1, wherein the phosphor layer comprises a thermographic based phosphor layer.

8. The thermal barrier coating spallation detection system of claim 7, wherein the thermographic based phosphor layer comprises a crystal.

9. The thermal barrier coating spallation detection system of claim 8, wherein the crystal comprises an yttrium aluminum garnet (YAG) crystal, a lutetium aluminum garnet (LuAG) crystal, a scandium aluminum garnet (ScAG) crystal, a yttrium aluminum boron nitrogen garnet (YABNG) crystal, an yttrium aluminum boron garnet (YABG) crystal, a quartz crystal, or a sapphire crystal.

10. The thermal barrier coating spallation detection system of claim 8, wherein the thermographic based phosphor layer comprises a rare earth element.

11. The thermal barrier coating spallation detection system of claim 10, wherein the rare earth element comprises neodymium (Nd), chromium (Cr), erbium (Er), ytterbium (Yb), cerium (Ce), dysprosium (Dy), or thulium (Tm).

12. The thermal barrier coating spallation detection system of claim 1, wherein the thermal barrier coating comprises a zirconia.

13. The thermal barrier coating spallation detection system of claim 1, wherein the hot gas path component comprises a substrate with a base coat thereon.

14. The thermal barrier coating spallation detection system of claim 13, wherein the phosphor layer is positioned between the thermal barrier coating and the base coat.

15. A method of inspecting a thermal barrier coating with an underlying phosphor layer of a hot gas path component for spallation, comprising:

emitting stimulant radiation at the thermal barrier coating;

receiving emission radiation from the thermal barrier coating;

comparing successive received emission radiation; and

indicating spallation of the thermal barrier coating if a change is shown in the successive received emission radiation caused by fluorescence of the phosphor layer.

16. A thermal barrier coating spallation detection system for a gas turbine engine, comprising:

a hot gas path component installed within the gas turbine;

the hot gas path component comprising a phosphor layer and a thermal barrier coating applied over the phosphor layer;

a stimulant radiation source;

an optical device;

wherein the optical device directs stimulant radiation at the thermal barrier coating and receives emission radiation; and

a digital camera in communication with the optical device;

wherein a change in the received emission radiation displayed on the digital camera caused by fluorescence of the phosphor layer indicates spallation of the thermal barrier coating.

17. The thermal barrier coating spallation detection system of claim 16, wherein the stimulant radiation source comprises a laser.

18. The thermal barrier coating spallation detection system of claim 16, wherein the digital camera comprises a pixel grid and wherein a change in the pixel grid indicates spallation of the thermal barrier coating.

19. The thermal barrier coating spallation detection system of claim 16, wherein the phosphor layer comprises a thermographic based phosphor layer.

20. The thermal barrier coating spallation detection system of claim 16, wherein the hot gas path component comprises a base coat and wherein the phosphor layer is positioned between the thermal barrier coating and the base coat.