Development of a flexible phased array electromagnetic acoustic testing system with array pickups

The thermal barrier coatings (TBCs) used to protect blades of heavy-duty gas turbines is prone to debonding defects during fabrication and service. It is difficult to detect the debonding defects in the TBC system non-destructively and in situ due to the curved shape of blade and the narrow space between the blades setting in the gas turbine. In this paper, a flexible phased array electromagnetic acoustic (FPA-EMA) testing system with array pickups is developed, which is capable to drive a flexible phased array electromagnetic acoustic transducer (FPA-EMAT) to generate and receive ultrasonic wave directly in the metallic substrate of TBCs, and is potential to be applied to the inspection of debonding defects in the TBC system of gas turbine blades. A phased array excitation unit, a multi-channel signal receiving unit and a new signal post-processing algorithm are developed for the new EMA testing system to enhance the surface acoustic wave in the layered structure and to improve the low conversion efficiency of the conventional EMA testing system. In addition, a bias magnetic field coil fed with long pulse current of large amplitude is adopted to make the new EMAT thin and flexible in order to be applied in a narrow space. The interfering noise and geometric size problems brought by the multiple excitation and pickup channels are well addressed in the new system. The good performances of the developed FPA-EMA testing system were verified experimentally and show the system of good potential to be applied to NDT of practical curved structures.