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<p>The thickness and uniformity of thermal barrier coatings (TBCs) on turbine blades are critical parameters for ensuring their performance and service life. However, effective full-surface inspection methods and systems remain scarce. To address this, the present study developed a multi-angle automatic scanning system that integrates a laser 3D scanner, an industrial robotic arm, and a precision linear module. The system separately scanned the surface point clouds of the substrate, sprayed, and polished components to generate a comprehensive full-surface point cloud of the blade. A method combining point cloud registration algorithms with distance calculations was then proposed to determine the sprayed coating thickness, the thickness removed by polishing, and the residual coating thickness at any location on the blade surface. Comparative analysis from case experiments demonstrated that the calculated coating thickness deviates by less than 10&#xa0;μm from the true thickness. Compared to traditional contact-type thickness gauges or destructive localized microscopic measurements, the proposed method offers advantages of being noncontact, nondestructive, highly accurate, and efficient, while providing detailed visualization of coating thickness uniformity over the entire blade surface.</p>

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Nondestructive Full-Surface Thickness Evaluation of Thermal Barrier Coatings Using a Robotic Multi-angle 3D Scanning and Point Cloud Analysis System

  • 期刊论文

  • 发表日期：

    2026年3月5日

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  • Tingyang Chen,
  • Shujuan Dong,
  • Zhenhua Cai,
  • Haixian Liu,
  • Chunming Deng

摘要

The thickness and uniformity of thermal barrier coatings (TBCs) on turbine blades are critical parameters for ensuring their performance and service life. However, effective full-surface inspection methods and systems remain scarce. To address this, the present study developed a multi-angle automatic scanning system that integrates a laser 3D scanner, an industrial robotic arm, and a precision linear module. The system separately scanned the surface point clouds of the substrate, sprayed, and polished components to generate a comprehensive full-surface point cloud of the blade. A method combining point cloud registration algorithms with distance calculations was then proposed to determine the sprayed coating thickness, the thickness removed by polishing, and the residual coating thickness at any location on the blade surface. Comparative analysis from case experiments demonstrated that the calculated coating thickness deviates by less than 10 μm from the true thickness. Compared to traditional contact-type thickness gauges or destructive localized microscopic measurements, the proposed method offers advantages of being noncontact, nondestructive, highly accurate, and efficient, while providing detailed visualization of coating thickness uniformity over the entire blade surface.