In Situ, Real-time Monitoring of the Properties of Engine Part Coatings

ABSTRACT: During this Phase I effort Control Vision, Inc. will focus on developing an In-Situ, Real-Time optical sensor for thermal spray process monitoring on gas turbine engine components. Several innovative optical test schemes will be tested both in the laboratory and in thermal spray production environments. Feedback from the thermal spray coating production industry from the beginning of the effort ensures the resultant sensor will work in the production environment. Multiple tests both in the laboratory and thermal spray booths allow a data driven assessment on various measuring techniques for coating thickness, their practicality, cost, and limitations. The final result of the Phase I program will be a clear understanding of the pluses and minuses of the various techniques both from a technical and practical view point. BENEFIT: Thermal spray is a highly complex process where numerous interrelated variables must be controlled to produce a reliable coating. While a great deal of energy has been focused on controlling these variables and understanding their connection there are still many unknown factors which can affect desired coating properties. Real time In-Situ measurement of coating properties would increase confidence in reliability and is the next logical step in producing"prime reliant"coatings. Furthermore, our proposed In-Situ measurement capability would have significant economic value, increasing booth efficiency by reducing the amount of booth time required to spray a component. In addition, all present methods of measuring coating thickness require a process interruption. This increases process variability which could be eliminated by measuring coating thickness during the coating process.