Non-destructive evaluation of defects in thermal barrier coating system using combined electromagnetic and thermographic signals

Jialun Li, Zongfei Tong, Qingning Yang, Jiahao Wang, Chenyu Jia, Wei Guo, Yuange Zhang, Peng Jiang, Wei Qiu, Tetsuya Uchimoto, Shejuan Xie (), Zhenmao Chen () and Tiejun Wang ()
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Jialun Li: Xi’an Jiaotong University
Zongfei Tong: Xi’an Jiaotong University
Qingning Yang: Xi’an Jiaotong University
Jiahao Wang: Xi’an Jiaotong University
Chenyu Jia: Xi’an Jiaotong University
Wei Guo: Xi’an Jiaotong University
Yuange Zhang: Xi’an Jiaotong University
Peng Jiang: Xi’an Jiaotong University
Wei Qiu: Tianjin University
Tetsuya Uchimoto: Aoba-ku
Shejuan Xie: Xi’an Jiaotong University
Zhenmao Chen: Xi’an Jiaotong University
Tiejun Wang: Xi’an Jiaotong University

Nature Communications, 2025, vol. 16, issue 1, 1-12

Abstract: Abstract Thermal barrier coating system plays key role in high temperature gas turbine blades. During the manufacture and in-service processes, defects are inevitable due to the inconsistent deformation and fatigue loading. The typical defects, e.g. interfacial debonding and crack in substrate, may significantly degrade the performance, safety and service life of gas turbine. However, it is challenging to non-destructively evaluate the small defects and/or coexistent multi-defects in thermal barrier coating system. Here, we propose a non-destructive method to detect the defects in thermal barrier coating system using the results of both infrared thermography and eddy current testing. Using this method, we detect interfacial debonding as small as 0.7 mm within 0.2 s and identify defect types which are essential for turbine blade fabrication and maintenance. By leveraging multi-physical fields, we achieve effective and quantitative evaluation of coexisting defects in thermal barrier coating system. This method integrates multiple non-destructive evaluation techniques and provides an approach to assess defects in multilayer structures without damaging them.

Date: 2025
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DOI: 10.1038/s41467-025-63717-3

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