Monitoring Delamination Progression in Thermal Barrier Coatings by Mid‐Infrared Reflectance Imaging

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Mid‐infrared (MIR) reflectance imaging is shown to be a reliable diagnostic tool for monitoring delamination progression in thermal barrier coatings (TBCs). MIR reflectance imaging utilizes the maximum transparency of TBCs in the 3–6 μm wavelength region to probe below‐surface delamination crack propagation that is typically hidden from visible wavelength inspection. The image contrast that identifies delamination progression arises from the increased reflectance produced by a large component of total internal reflection at the TBC/buried‐crack interface. Imaging was performed at a wavelength of 4 μm to take advantage of the relatively high transmittance of plasma‐sprayed 8 wt% yttria‐stabilized zirconia (8YSZ) TBCs along with a desirable relative insensitivity to potentially interfering absorptions by atmospheric constituents at that wavelength. A key advantage of MIR reflectance imaging over competing techniques is that it is sensitive to delamination progression even at very early stages before delamination cracks start linking together; therefore, TBC health assessment can be achieved throughout the life of the TBC well before TBC failure is imminent. Examples are presented to demonstrate monitoring delamination progression by MIR reflectance imaging in 8YSZ TBC‐coated specimens subjected to furnace cycling to 1163°C. The experimental results were in good agreement with reflectance values predicted by a four‐flux Kulbelka–Munk approximation applied to the extreme cases of a completely adherent and a completely detached TBC. Practical considerations, including potential interfering effects from surface contamination, sintering, and erosion are discussed.