An organic protective coating system plays an important role for the corrosion protection of offshore metallic structures. It is of practical importance to detect possible coating defects and evaluate coating performance for corrosion degradation monitoring. Reliable defect identification can provide timely and effective maintenance to avoid serious consequences. This work investigated various multilayer organic coating systems by terahertz pulse imaging technology and aimed to explore the inspection ability of terahertz non-destructive testing (THz NDT) of protective coatings. Several types of defective coating samples were measured. The comparison of measurements obtained for sites with and without defects was provided. The changes in the signals caused by the presence of defects were explained. Structural analysis, quantitative evaluation, and defect identification were carried out in detail. The results of measurements showed that corrosion defects, paint bulge defects, and paint detachment defects can be distinguished and identified in combination with the causes of defects. It can provide effective technical guidance for terahertz technology to be gradually extended to engineering applications.

While thermal barrier coatings (TBCs) are being sprayed onto aero-engine turbine blades, or while the engine blade is working, high temperatures and strong impact forces will damage TBCs under thermal cycles, resulting in the coating peeling off from the blades. The current method of using ECT, IRT, or another method alone cannot achieve the real-time detection of coating defects with both high precision and high penetration power. Two detection methods, namely, terahertz pulsed imaging (TPI) and optical coherence tomography (OCT), were combined to evaluate typical defects observed in TBCs (including internal debonding cracks, surface high-temperature cracks, and surface etched cracks). The results showed that the OCT system successfully obtained the micron-level axial resolution, but the detection depth of the OCT system was limited. The TPI system achieved a higher penetration depth than OCT—hence, it can be used for the nondestructive detection and evaluation of the internal debonding defects in the sample—but its resolution needs to be improved. Following this conclusion, a method is proposed using TPI and OCT concurrently for the nondestructive testing and quantitative evaluation of TBCs on etched cracks, thus achieving progress both in terms of depth and resolution. In our experiment, defects with a depth of 519 μm and a width of 100 μm were measured. The proposed method is suitable for situations where multiple defects in TBC samples of blades need to be detected simultaneously during the working process. When there are defects deep inside the sample, more small cracks on the surface can be evaluated to achieve a combination of depth and accuracy.