INNOVATIVE APPROACHES FOR IN-SITU ASSESSMENT OF THERMAL SPRAY COATING PROPERTIES ON AERO-ENGINE COMPONENTS

ABSTRACT: ReliaCoat Technologies, LLC, a Stony Brook University based spin-off, in conjunction with program collaborators GE Aviation, Sulzer Metco, Argonne National Lab and Stony Brook University, proposes to develop innovative approaches for in-situ measurement methodologies and tools on real parts and components. The in-situ measurement of coating properties on real engine parts is perhaps the most significant capability for the thermal spray industry, yet the implementation of such technology was not possible due to high financial risk and difficulty in implementation. The proposed innovation is based on collaboration of extensive ex-situ thermal spray coating property measurement experience with expert knowledge in laser-based measurements and thermal imaging because conductivity measurement (Argonne National Laboratory). The in-situ component property measurement system will be incorporating coating physical measurement (thickness), relevant coating property (thermal conductivity) and subsequent data validation through ReliaCoat curvature based in-situ coating property sensor. Through the multiphase SBIR program, the team will demonstrate both in situ thickness and in situ thermal conductivity measurement on engine component within a thermal spray booth with transition plans to OEM approved spray shops and air force overhaul depots. Exploratory evaluation of more complex laser ultrasonic based modulus measurement system will also be considered. BENEFIT: Thermal spray coatings are crucial to economic, safe and reliable operation of gas turbine engines used for propulsion and energy generation. Both US military and commercial turbine industry uses a vast array of thermal spray coatings both in original equipment manufacturer, and in overhaul and repair. This represents a multi-billion dollar industry in the US. However, lack of in-situ sensors for relevant property measurements at the component level has impeded the advancement of TS coating to prime reliance. Incorporation of simple coating thickness sensor in each production booth will provide fast part turnaround time by eliminating torch on-off period. Furthermore, in-situ thermal conductivity sensor will empower both coating engineer and applicator with the ability of measuring each and every parts that will greatly reduce the part rejection rate, resulting in cost savings associated with reduced rework, increased efficiency and productivity. These enhancements in in-situ sensor technology will benefit to both military and civilian applications of thermal spray coatings.