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Infrared Thermography as a Non-destructive Testing Solution for Thermal Spray Metal Coatings

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Abstract

In this work, an infrared (IR) thermographic procedure was evaluated as a non-destructive testing tool to detect damage in thermal spray metallic coatings. As model systems, polished HVOF- and HVAF-sprayed Fe-based layers deposited onto steel plates were employed. Damage by external-object impingement was simulated through a cyclic impact-test apparatus, which induced circumferential and radial cracks across all model systems, and interface cracks of different sizes in distinct samples. Damaged and undamaged plates were bulk-heated to above 100 °C using an IR lamp; their free-convection cooling was then recorded by an IR thermocamera. The intentionally induced defects were hardly detectable in IR thermograms, due to IR reflection and artificial “hot” spots induced by residuals of transfer material from the impacting counterbody. As a micrometer-thin layer of black paint was applied, surface emissivity got homogenized and any artifacts were effectively suppressed, so that failed coating areas clearly showed up as “cold spots.” This effect was more apparent when large interface cracks occurred. Finite-element modeling proved the physical significance of the IR-thermography approach, showing that failed coating areas are cooled by surrounding air faster than they are heated by conduction from the hot substrate, which is due to the insulating effect of cracks.

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Acknowledgments

The authors wish to thank Prof. P. Tartarini (Università degli Studi di Modena e Reggio Emilia, Italy) for providing IR-thermography instrumentation. Mr. G. Urso and CIGS (Centro Interdipartimentale Grandi Strumenti) at Università degli Studi di Modena e Reggio Emilia, Italy, are also acknowledged.

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Authors and Affiliations

  1. Dipartimento di Ingegneria “Enzo Ferrari”, Università degli Studi di Modena e Reggio Emilia, Via P. Vivarelli 10, 41125, Modena, Italy

    Paolo E. Santangelo, Giulio Allesina, Giovanni Bolelli & Luca Lusvarghi

  2. Laboratory of Materials Science, Faculty of Engineering Sciences, Tampere University of Technology, Korkeakoulunkatu 6, Tampere, Finland

    Ville Matikainen & Petri Vuoristo

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  1. Paolo E. Santangelo
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  2. Giulio Allesina
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  5. Ville Matikainen
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Correspondence to Giovanni Bolelli.

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Santangelo, P.E., Allesina, G., Bolelli, G. et al. Infrared Thermography as a Non-destructive Testing Solution for Thermal Spray Metal Coatings. J Therm Spray Tech 26, 1982–1993 (2017). https://doi.org/10.1007/s11666-017-0642-6

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  • DOI: https://doi.org/10.1007/s11666-017-0642-6

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