COMPLEX GEOMETRIES

BACKGROUND

Field

[0001] Embodiments of the present disclosure generally relate to determining thickness of three-dimensional (3D) object coatings. More particularly, embodiments of the present disclosure relate to determining thickness of protective coatings for turbine blades and other components exposed to corrosive environments.

Description of the Related Art

[0002] Aerospace components including turbine vanes and blades are fabricated from nickel and cobalt-based superalloys Supera!!oy protection during engine operation employs a plurality of layers, including a stable oxide scale that is dense, adheres to the surface or surfaces of the component, and is stable at high temperatures up to about 1900 °C. Various barrier coatings, including thermal barrier coatings (TBCs), can be used to inhibit oxidation and corrosion of the aerospace components. Various materials are employed to form these corrosion- resistant coatings, such as native-grown oxides include Cr203 for hot corrosion protection and AI2O3 for oxidation resistance. TBCs and other barrier coatings can be deposited using either e-beam PVD or thermal spray. Deposited TBCs include yttria-stabilized zirconia, gadolinium zirconate, tantalum-yttrium zirconium oxides, and other mixed zirconate, baifnate, silicate, and aluminate compounds. However, measuring TBC thickness on three-dimensional (3D) objects may be destructive, inaccurate, costly, and time-consuming.

[0003] Thus, there remains a need in the art for measuring coating thicknesses of 3D objects with non-destructive imaging methods.

SUMMARY

[0004] in one embodiment, a method of determining a thickness of an object coating is provided. The method includes, in a non-destructive measurement device having at least one image sensor system, positioning an uncoated surface of an object in a field view of the at least one image sensor system. The object has one or more surfaces. A first 3D image of the uncoated surface is collected without chemically or physically changing the one or more surfaces of the object. The first 3D image corresponds to a first surface profile of the uncoated surface. A coated surface of the object is positioned in the field view of the at least one image sensor system. A second 3D image of the coated surface is collected without chemically or physically changing the one or more surfaces of the object. The second 3D image corresponds to a second surface profile of the coated surface. The first 3D image and the second 3D image are analyzed.

[0005] In another embodiment, a method of determining a thickness of an object coating is provided. The method includes in a non-destructive measurement device having at least one image sensor system, positioning a surface of an object in a field view of the at least one image sensor system. The object has one or more surfaces and the surface having a uncoated portion and a coated portion. A 3D image of the surface is collected without chemically or physically changing the one or more surfaces of the object. The 3D image corresponds to a first surface profile of the uncoated portion and a second surface profile of the coated portion. The 3D image is analyzed.

[0006] In yet another embodiment, a non-destructive measurement device is provided. The non-destructive measurement device includes a body, a stage assembly disposed in the body having a stage configured to retained an object and a coordinate grid, an image sensor assembly disposed in the body, an alignment mechanism disposed in the body, and a controller. Each of the one or more image sensor systems has an illumination unit, one or more image sensors, and a Quick Response (QR) code reader. The alignment mechanism operable to align position the object at an alignment position on the coordinate grid. The alignment position corresponds to the QR code of the object. The controller is coupled to the stage assembly, the image sensor assembly, and the alignment mechanism. The controller is interfaced with a coating system and controls automation integration with the coating system via a system controller of the coating system. The controller is configured to instruct the one or more image sensor systems to collect one or more 3D images of one or more surfaces of the object analyze the one or more 3D images to obtain a thickness of a coating of the object. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, and may admit to other equally effective embodiments.

[0008] Figure 1 is a schematic view of a coating system having an at least one integrated non-destructive measurement device according to an embodiment.

[0009] Figure 2A is a schematic cross-sectional view of a non-destructive measurement according to an embodiment.

[0010] Figure 2B is a schematic top view of a non-destructive measurement according to an embodiment.

[0011] Figure 2C is a schematic view of an image sensor system according to an embodiment.

[0012] Figure 3 is a flow diagram of a sub-method of a non-destructive measurement method for determining coating thickness of a 3D object according to an embodiment.

[0013] Figure 4 is a flow diagram of a sub-method of a non-destructive measurement method for determining coating thickness of a 3D object according to an embodiment.

[0014] Figure 5 is a flow diagram of a method for determining coating thickness of a 3D object.

[001 S] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation. DETAILED DESCRIPTION

[0016] Embodiments described herein relate to a non-destructive measurement device measurement device and a non-destructive measurement method for determining coating thickness of a three-dimensional (3D) object.

[0017] Figure 1 is a schematic view of a coating system 100 having an at least one integrated non-destructive measurement device 102. Additionally, the non destructive measurement device 102 may be provided as a standalone device unattached and remote from the system 100. The system 100 and the integrated non-destructive measurement device 102 are utilized for coating 3D objects and measuring coating thicknesses on 3D objects with non-destructive imaging methods. It is to be understood that the system described below is an exemplary system and other systems, including systems from other manufacturers, may be used with or modified to accomplish aspects of the present disclosure. The system 100 includes one or more non-destructive measurement devices 102 and one or more of coating modules 104 coupled to a transfer chamber 106. In one embodiment, which can be combined with other embodiments described herein, the system 100 includes one or more processing modules 108 coupled to the transfer chamber 106. The one or more coating modules 104 are adapted for coating 3D objects. In one embodiment, which can be combined with other embodiments described herein, the 3D objects include aerospace components, such as turbine vanes and blades. In another embodiment, which can be combined with other embodiments described herein, the coatings are barrier coatings, such as thermal barrier coatings (TBCs). The one or more processing modules are adapted for processing the 3D objects, and the like. The transfer chamber 106 houses a transfer mechanism 110 used to transfer 3D objects between the measurement devices 102, coating modules 104, and processing modules 108.

[0018] A system controller 112 is coupled to and controls each module and measurement device 102 of the system 100. Generally, the system controller 112 may control all aspects of operation of the system 100 using a direct control of modules and measurement devices 102 of the system 100 or, alternatively, by controlling the computers associated with these modules and the measurement devices 102. Furthermore, the system controller 112 is interfaced with a controller 208 (shown in Figure 2A) associated with the measurement device 102. The controller 208 controlling automation integration with the system 100 via the system controller 112. For example, movements of the transfer mechanism 110, transferring 3D objects to and from the measurement devices 102 and coating modules 104, performing process sequences, coordinating operations of the measurement devices 102, and so on, may be controlled by the system controller.

[0019] In operation, the system controller 112 enables feedback from each module and measurement device 102 to optimize 3D object throughput. The system controller 112 comprises a central processing unit (CPU) 114, a memory 118, and a support circuit 118. The CPU 114 may be one of any form of a general purpose computer processor that can be used in an industrial setting. The support circuit 118 is conventionally coupled to the CPU 114 and may comprise cache, clock circuits, input/output subsystems, power supplies, and the like. The software routines, when executed by the CPU 114, transform the CPU into a specific purpose computer (controller). The software routines may also be stored and/or executed by a second controller (not shown) that is located remotely from the measurement device 102.

[0020] Figure 2A is a schematic cross-sectional view of a measurement device 102. Figure 2B is a schematic top view of the measurement device 102. Figure 2C is a schematic view of an image sensor system 212. In one embodiment, which can be combined with other embodiments described herein, the measurement device 102 is utilized for non-destructive methods of measuring coating thicknesses of 3D objects. The measurement device 102 includes a body 200, a stage assembly 202, an image sensor assembly 204, an alignment mechanism 206, and controller 208. The stage assembly 202 includes a stage 210 configured to retain an object 101. In one embodiment, which can be combined with other embodiments described herein, the object 101 is a three-dimensional (3D) object. In another embodiment, which can be combined with other embodiments described herein, the stage 210 is a goniometric stage and/or optical stage. The stage 210 is configured to rotate the object 101 about at least one of an x-axis, y-axis, and z-axis of the stage 210 to position one or more of surfaces 103 of the object 101 in relation to one or more image sensor systems 212 of the image sensor assembly 204. The stage 210 includes an actuator 222 that moves the stage 210 between a measurement position (as shown) and a transfer position. The actuator 222 facilitates object transfer to and from the measurement device 102 through an opening 224 formed though the body 200 and sealable by a door 226. In one embodiment, which can be combined with other embodiments described herein, the actuator 222 is operable to rotate the object 101 about at least one of the x~axis, y~axis, and z-axis of the stage 210. The stage 210 includes a coordinate grid 214 disposed thereon. The coordinate gird 214 is utilized for the non-destructive methods of measuring coating thicknesses of 3D objects described herein.

[0021] The controller 208 is coupled to the stage assembly 202, the one or more image sensor systems 212, and the alignment mechanism 206. The controller 208 includes a central processing unit (CPU) 216, a memory 218, and support circuits (or I/O) 220. The CPU 216 is one of any form of computer processors used in industrial settings for controlling various processes and hardware (e.g., goniometers, motors, and other hardware) and/or monitoring the processes (e.g., processing time and object 101 position). The memory 218 is connected to the CPU 216. The memory 218 is one or more of a readily available memory, such as random access memory (RAM), read only memory (ROM), floppy disk, hard disk, or any other form of digital storage, local or remote. Software instructions and data are coded and stored within the memory 218 for instructing the CPU 216. The support circuits 220 are also connected to the CPU 216 for supporting the processor in a conventional manner. The support circuits include conventional cache, power supplies, clock circuits, input/output circuitry, subsystems, and the like. A program (or computer instructions), which may be referred to as an imaging program, is readable by the controller determines which tasks are performabie on the object 101. The program is software readable by the controller and includes code to monitor and control, for example, the processing time and object 101 position. In one embodiment, which can be combined with other embodiments described herein, the memory 218 includes image acquisition software, image analysis software, image numbering software to determine position and orientation of the object 101 , a data base with part numbers and image information, each number corresponding to an object 101 and each image information corresponding to the object 101 of the part number, and/or software that outputs thickness of the object 101 and/or one or more surfaces 103 of the object 101.

[0022] The image sensor assembly 204 includes the image sensor systems 212. In one embodiment, which can be combined with other embodiments described herein, the image sensor assembly 204 includes each of the one or more image sensor systems 212 are in fixed positions oriented toward, i.e. , facing the field of view 211 of the image sensor systems 212, a surface of the one or more surfaces 103 of the object 101 Therefore, rotation of the stage 210 and movement of the one or more image sensor systems 212 are not required for the non-destructive imaging methods described herein. In another embodiment, which can be combined with other embodiments described herein, the imaging sensor assembly 204 includes only one image sensor system 212 and the rotation of the stage 210 is utilized to position each of the one or more surfaces 103 in an orientation toward the image sensor system 212. In yet another embodiment, as shown, which can be combined with other embodiments described herein, the one or more image sensor systems 212 are operable to be oriented toward each of the one or more surfaces 103. For example, the one or more image sensor systems 212 are coupled a track 228 disposed in the body 200 and around a circumference 231 of the stage 210. In one embodiment, which can be combined with other embodiments described herein, the track 228 is a rail or cable. Each of the one or more image sensor systems 212 includes an actuator 230 that move the one or more image sensor systems 212 along the track 228 around the circumference 231 of the stage 210.

[0023] In embodiments described herein, which can be combined with other embodiments described herein, multiple 3D objects are coated utilizing the system 100 and the coating thickness of each of the multiple 3D objects are measured utilizing at least one non-destructive measurement device 102. The multiple 3D objects include different pluralities of 3D objects and the alignment mechanism 206 is operable to position each 3D object of each plurality of the different pluralities of 3D objects in substantially the same positon on the stage 210. Measuring the coating thickness each 3D object of each plurality of the different pluralities of 3D objects from substantially the same positon allows for part coordinates each 3D object of each plurality of the different pluralities of 3D objects to be in substantially the same positon. In one embodiment, which can be combined with other embodiments described herein, the alignment mechanism 206 includes an actuated arm mechanism 232 and a gripper 234. The actuated arm mechanism 232 and the gripper 234 allows the alignment mechanism 206 to capture the object 101 on the stage 210 and align the object 101 by positioning the object 101 at an alignment position 236 of coordinate gird 214 of the stage 210.

[0024] Referring to Figure 1 , the system 100 having the one or more integrated non-destructive measurement devices 102 may be utilized in concurrently with a non-destructive measurement method 500 for determining coating thickness of a 3D object. Multiple 3D objects are coated utilizing the system 100 and the coating thickness of each of the multiple 3D objects are measured utilizing at least one non destructive measurement device 102. For example, an uncoated 3D object of a one of the pluralities of 3D objects is measured in a first measurement device and a coated 3D object of a one of the pluralities of 3D objects is measured in a second measurement device of the one or more integrated non-destructive measurement devices 102. Concurrently, 3D objects are coated in the one or more of coating modules 104. The system controller 112 controls movements of the transfer mechanism 110, transferring 3D objects to and from the measurement devices 102 and coating modules 104, and is interfaced with the controller 208 for performing the method 500.

[0025] The image sensor system 212 includes an illumination unit 201 and one or more image sensors 203. In one embodiment, which can be combined with other embodiments described herein, the one or more image sensors 203 are cameras. In a first configuration, also known as a time-of-flight configuration, the illumination unit 201 is configured to project one or more pulses of light, such as infrared light, on the one or more surfaces 103 of the object 101 without chemically or physically changing the one or more surfaces 103 of the object 101. Each of the one or more image sensors 203 coupled to the controller 208 having a timing mechanism determine the time-of-flight of the one or more pulses of light from the one or more surfaces 103 of the object 101 to each of the one or more image sensors 203. Determining the time-of-flight of the one or more pulses of light from the one or more surfaces 103 of the object 101 to each of the one or more image sensors 203 allows for z-axis positions (zi, Z2, . . . ,z _n ) on a z-axis 207 of the one or more surfaces 103 to be determined to generate a 3D image of the one or more surfaces 103.

[0026] In a second configuration, also known as a structured light configuration, the illumination unit 201 is configured to project a fringe pattern on the one or more surfaces 103 of the object 101 without chemically or physically changing the one or more surfaces 103 of the object 101. The beams of light are reflected off the one or more surfaces 103 and one or more images are collected by the one or more image sensors 203. Each of the one or more image sensors 203 has a field of view 211. The distances between the beams of light captured in the one or more images collected by the one or more image sensors 203 allows for the z-axis positions (zi, Z2, . . . ,zn) on a z-axis 207 of the one or more surfaces 103 to be determined to generate a 3D image of the one or more surfaces 103.

[0027] As shown in Figure 2C, the surface 103 of the object 101 has at least one part coordinate 213. Each part coordinate 213 includes an x-position (xi, X2, . . . ,x _n ) on an x~axis 205 and a y-position (yi, i, . . . ,yn) on an y-axis 209. The x-axis 205, y-axis 209, and z-axis 207 are relative the image sensor system 212 facing the surface 103. Thus, each of the one or more surfaces 103 has at least one part coordinate on the x-axis 205 and the y-axis 209 of the coordinate gird 214. The image sensor system 212 includes a Quick Response (QR) code reader 215 operable to read a QR code 217 disposed on the object 101. Each plurality of 3D objects of the pluralities of 3D objects has a different QR code 217 The image sensor system 212 is coupled to the controller 208 such that the QR code is provided to controller 208 The controller instructs the image sensor system 212 to determine the z-axis positions of each part coordinate 213 of the object 101 corresponding to the QR code 217.

[0028] Figure 3 is a flow diagram of a sub-method 300 of non-destructive measurement method 500 for determining coating thickness of a 3D object. In one embodiment, which can be combined with other embodiments described herein, the measurement device 102 is utilized for the sub-method 300. At operation 301 , the QR code 217 of an uncoated object 101 is read by the QR reader 215 and the aligned on the stage 210 at the alignment position 236 corresponding to the QR code 217. At optional operation 302, the image sensor system 212 determines the z-axis position of each part coordinate 213 of a first uncoated surface of the object 101. At operation 303, a 3D image of the first uncoated surface of the object 101 is collected by the image sensor system 212. At operation 304, optional operation 302 and operation 303 are repeated for a predetermined number of uncoated surfaces. In one embodiment, which can be combined with other embodiments described herein, the image sensor assembly 204 includes each of the one or more image sensor systems 212 in fixed positions facing a surface of the one or more surfaces 103 of the object 101. Therefore, the z-axis positions are determined and 3D images are collected without rotating the object 101. In other embodiments, which can be combined with other embodiments described herein, the object 101 is rotated by the stage 210 and/or the one or more image sensor systems 212 are moved around the circumference 231 of the stage 210. At operation 305, the uncoated object 101 is removed from the stage 210 and coated. At operation 306, operations 301 -304 are repeated for the coated object 101.

[0029] Figure 4 is a flow diagram of a sub-method 400 of non-destructive measurement method 500 for determining coating thickness of a 3D object. In one embodiment, which can be combined with other embodiments described herein, the measurement device 102 is utilized for the sub-method 400. At operation 401 , the QR code 217 of an object 101 is read by the QR reader 215 and the aligned on the stage 210 at the alignment position 236 corresponding to the QR code 217. The object 101 includes one or more surfaces 103. At optional operation 402, the image sensor system 212 determines the z-axis position of each part coordinate 213 of the one or more surfaces. At operation 403, a 3D image of each of the one or more surfaces 103 is collected. In one embodiment, which can be combined with other embodiments described herein, at least one surface of the one or more surfaces 103 is uncoated and at least one surface of the one or more surfaces is coated. In another embodiment, which can be combined with other embodiments described herein, at least one surface of the one or more surfaces 103 has a coated portion and an uncoated portion. In one embodiment, which can be combined with other embodiments described herein, the image sensor assembly 204 includes each of the one or more image sensor systems 212 in fixed positions facing the one or more surfaces 103 of the object 101. Therefore, the z-axis positions are determined and 3D images are collected without rotating the object 101. In other embodiments, which can be combined with other embodiments described herein, the object 101 is rotated by the stage 210 and/or the one or more image sensor systems 212 are moved around the circumference 231 of the stage 210.

[0030] Figure 5 is a flow diagram of a method 500 for determining coating thickness of a 3D object. In one embodiment, which can be combined with other embodiments described herein, the measurement device 102 is utilized for the method 500. At operation 501 , one of the sub-method 300 and the sub-method 400 are performed to collect one or more 3D images. In one embodiment, which can be combined with other embodiments described herein, one of the sub-method 300 and the sub-method 400 are performed to collect at least one first 3D image of an uncoated surface of the object 101 and at least one second 3D image of a coated surface of the object 101. In the embodiment, the uncoated surface and coated surface correspond to a same surface of the one or more surfaces 103 of the object 101. In another embodiment, which can be combined with other embodiments described herein, the sub-method 400 collects at least one first 3D image of a surface having an uncoated portion and a coated portion. The first 3D image include z-axis positions (zi, zz, . . . ,z _n ) on the z-axis 207 of the surface of the first 3D image. The second 3D image include z-axis positions (zi, Z2, . . . ,z _n ) on the z-axis 207 of the surface of the second 3D image.

[0031] At optional operation 502, the one or more 3D images are mirrored in the z-axis 207. The mirrored one or more 3D images correspond to surface profiles. In one embodiment, which can be combined with other embodiments described herein, the first 3D image is mirrored in the z-axis 207 such that a mirrored 3D image corresponds to a first surface profile of the uncoated surface. In another embodiment, which can be combined with other embodiments described herein, the first 3D image is mirrored in the z-axis 207 such that a mirrored first 3D image corresponds to the first surface profile of the uncoated portion and a second surface profile of the coated portion of the surface. A mirrored second 3D image corresponds to the second surface profile of the coated surface. At operation 503, outliers of the one or more 3D images are removed. In one embodiment, which can be combined with other embodiments described herein, outliers the first 3D image and the second 3D image are removed. At optional operation 504, areas of the one or more 3D images are selected for operations 505-507. In one embodiment, which can be combined with other embodiments described herein, the first 3D image and the second 3D image are selected for operations 505-507. At operation 505, the one or more 3D images are filtered. In one embodiment, which can be combined with other embodiments described herein, the first 3D image and the second 3D image are filtered. In one embodiment, which can be combined with other embodiments described herein, the first 3D image and the second 3D image are filtered utilizing a Gaussian filter. Filtering the first 3D image and the second 3D image removes one of image noise and surface roughness.

[0032] At optional operation 506, the one or more 3D images are overlapped. In one embodiment, which can be combined with other embodiments described herein, the first 3D image and the second 3D image are overlapped. When the first 3D image includes the uncoated portion and the coated portion it is not necessary to overlap the first 3D image and the second 3D image because the second 3D image is not collected. At operation 507, the surface profiles of the one or more images are subtracted. In one embodiment, which can be combined with other embodiments described herein, the second surface profile is subtracted first surface profile to obtain a thickness of the coating. At optional operation 508, operations 502-507 are repeated. In one embodiment, which can be combined with other embodiments described herein, operations 502-507 are repeated for at least one subsequent first 3D image and at least one subsequent second 3D image collected from one of the sub-method 300 and the sub-method 400. In another embodiment, which can be combined with other embodiments described herein, operations 501 - 508 are repeated to collect and analyze one or more 3D images of additional surfaces.

[0033] In summation, a non-destructive measurement device measurement device and a non-destructive measurement method for determining coating thickness of a three-dimensional (3D) object are provided. The utilization non destructive image collection methods in addition to the time-of-flight configuration and structured light configuration of the image sensor system allow for the determining coating thickness of a 3D object without chemically or physically changing the one or more surfaces of the object. [0034] While the foregoing is directed to examples of the present disclosure, other and further examples of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow