Effective control of the micro- and nanostructure of thermal barrier coatings is essential to enhance the thermal radiation performance of the coating, which helps to determine the remaining service life of the coating. This paper proposed a method to measure the radiation properties of thermal barrier coatings by terahertz nondestructive testing technique, using APS-prepared thermal barrier coatings as the object of study. Radiative properties were a comprehensive set of properties characterized by the diffuse reflectance, transmittance, and absorptance of the thermal barrier coating. The coating data in actual service were obtained by scanning electron microscopy and metallographic experiments, and the data were used as the simulation model critical value. The terahertz time-domain simulation data of coatings with different microstructural features were obtained using the finite-different time-domain (FDTD) method. In simulating the real test signals, white noise with a signal-to-noise ratio of 20 dB was added, and fast Fourier transform (FFT), short-time Fourier transform (STFT), and wavelet transform (WT) were used to reduce the noise and compare their noise reduction effects. Different machine learning methods were used to build the model, including support vector machine algorithm (SVM) and k-nearest neighbor algorithm (KNN). The principal component algorithm (PCA) was used to reduce the dimensionality of terahertz time-domain data, and the SVM algorithm and KNN algorithm were optimized using the particle swarm optimization algorithm (PSO) and the ant colony optimization algorithm (ACO), respectively, to improve the robustness of the system. The K-fold cross-validation method was used to construct the model to improve the adaptability of the model. It could be clearly seen that the novel hybrid PCA-ACO-SVM model had superior prediction performance. Finally, this work proposed a novel, convenient, nondestructive, online, safe and highly accurate method for measuring the radiation performance of thermal barrier coatings, which could be used for the judgment of the service life of thermal barrier coatings.

Accurately characterizing the internal porosity rate of thermal barrier coatings (TBCs) was essential for prolonging their service life. This work concentrated on atmospheric plasma spray (APS)-prepared TBCs and proposed the utilization of terahertz non-destructive detection technology to evaluate their internal porosity rate. The internal porosity rates were ascertained through a metallographic analysis and scanning electron microscopy (SEM), followed by the reconstruction of the TBC model using a four-parameter method. Terahertz time-domain simulation data corresponding to various porosity rates were generated employing the time-domain finite difference method. In simulating actual test signals, white noise with a signal-to-noise ratio of 10 dB was introduced, and various wavelet transforms were utilized for denoising purposes. The effectiveness of different signal processing techniques in mitigating noise was compared to extract key features associated with porosity. To address dimensionality challenges and further enhance model performance, kernel principal component analysis (kPCA) was employed for data processing. To tackle issues related to limited sample sizes, this work proposed to use the Siamese neural network (SNN) and generative adversarial network (GAN) algorithms to solve this challenge in order to improve the generalization ability and detection accuracy of the model. The efficacy of the constructed model was assessed using multiple evaluation metrics; the results indicate that the novel hybrid WT-kPCA-GAN model achieves a prediction accuracy exceeding 0.9 while demonstrating lower error rates and superior predictive performance overall. Ultimately, this work presented an innovative, convenient, non-destructive online approach that was safe and highly precise for measuring the porosity rate of TBCs, particularly in scenarios involving small sample sizes facilitating assessments regarding their service life.

With the development of high-efficiency gas turbine engines and increasing inlet temperatures, the performance of thermal barrier coatings (TBCs) for hot-section components has been more severely challenged. The doping of multi-element rare earth elements significantly improves the thermodynamic properties and chemical compatibility of thermal barrier coatings so that the application performance of coatings in high-temperature environments is enhanced considerably. In this work, the doped coatings prepared by REYSZ (RE = La, Sm, Nd) were investigated and characterized in terms of crystal structure, elastic properties, and thermal–mechanical properties based on the first-principles approach, combined with various empirical and semi-empirical formulations, and a predictive model for resistance to CMAS corrosion based on machine learning approaches. The results showed that the tetragonal phase REYSZ material was mechanically stable, had a large strain damage tolerance, and was not easy to fracture under applied loads and thermal shocks. In terms of CMAS corrosion resistance, the NdYSZ interfacial model had a lower surface energy (3.130 J/m²) and Griffith fracture energy (6.934 J/m²) compared with the conventional YSZ model, and Nd₂O₃ had the potential to improve the CMAS corrosion resistance of zirconia-based material for thermal barrier coatings. By evaluating the machine learning prediction models, the regression coefficients of the two algorithms were 0.9627 and 0.9740, and both these two prediction models showed high prediction accuracy and strong robustness. Ultimately, this work presented a novel mechanism–data hybrid method, which would facilitate the efficient development of TBC new materials for anti-CMAS corrosion.

Thickness inspection of thermal barrier coatings is crucial to safeguard the reliability of high-temperature components of aero-engines, but traditional destructive inspection methods are difficult to meet the demand for rapid assessment in the field. In this study, a new non-destructive testing method integrating terahertz time-domain spectroscopy and machine learning algorithms is proposed to systematically study the thickness inspection of 8YSZ coatings prepared by two processes, namely atmospheric plasma spraying (APS) and electron beam physical vapor deposition (EB-PVD). By optimizing the preparation process parameters, 620 sets of specimens with thicknesses of 100–400 μm are prepared, and three types of characteristic parameters, namely, time delay Δt, frequency shift Δf, and energy decay η, are extracted by combining wavelet threshold denoising and time-frequency joint analysis. A CNN-RF cascade model is constructed to realize coating process classification, and an attention-LSTM and SVR weighted fusion model is developed for thickness regression prediction. The results show that the multimodal feature fusion reduces the root-mean-square error of thickness prediction to 8.9 μm, which further improves the accuracy over the single feature model. The classification accuracy reaches 96.8%, of which the feature importance of time delay Δt accounts for 62%. The hierarchical modeling strategy reduces the detection mean absolute error from 6.2 μm to 4.1 μm. the method provides a high-precision solution for intelligent quality assessment of thermal barrier coatings, which is of great significance in promoting the progress of intelligent manufacturing technology for high-end equipment.

The gradual growth of oxides inside thermal barrier coatings is a key factor leading to the degradation of thermal barrier coating performance until its failure, and accurate monitoring of the growth stress during this process is crucial to ensure the long-term stable operation of engines. In this study, terahertz time-domain spectroscopy was introduced as a new method to characterize the growth stress in thermal barrier coatings. By combining metallographic analysis and scanning electron microscope (SEM) observation techniques, the real microstructure of the oxide layer was obtained, and an accurate simulation model of the oxide growth was constructed on this basis. The elastic solutions of the thermally grown oxide layer of thermal insulation coatings were obtained by using the controlling equations in the rate-independent theoretical model, and the influence of the thickness of the thermally grown oxide (TGO) layer on the stress distribution was explored. Based on experimental data, multidimensional 3D numerical models of thermal barrier coatings with different TGO thicknesses were constructed, and the terahertz time-domain responses of oxide coatings with different thicknesses were simulated using the time-domain finite difference method to simulate the actual inspection scenarios. During the simulation process, white noise with signal-to-noise ratios of 10 dB to 20 dB was embedded to approximate the actual detection environment. After adding the noise, wavelet transform (WT) was used to reduce the noise in the data. The results showed that the wavelet transform had excellent noise reduction performance. For the problems due to the large data volume and small sample data after noise reduction, local linear embedding (LLE) and kernel-based extreme learning machine (KELM) were used, respectively, and the kernel function was optimized using the gray wolf optimization (GWO) algorithm to improve the model’s immunity to interference. Experimental validation showed that the proposed LLE-GWO-KELM hybrid model performed well in predicting the TGO growth stress of thermal insulation coatings. In this study, a novel, efficient, nondestructive, online, and high-precision measurement method for the growth in TGO stress of thermal barrier coatings was developed, which provides reliable technical support for evaluating the service life of thermal barrier coatings.