Component with Magnetically Monitorable Protective Layer and Method for Operating a Component

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This invention relates to a component designed for high-temperature applications, such as turbine parts, which includes a non-ferromagnetic protective layer containing a special sensor material. The sensor material's local magnetic properties respond to the protective layer's material changes or accumulated temperature exposure, allowing non-destructive, external magnetic testing. This enables early detection of protective layer degradation due to corrosion or oxidation, supporting more precise, condition-based maintenance and reducing unexpected failures.

Use CasesContent extracted from patent full text and abstract with AI.

• Monitoring the health and remaining lifetime of gas turbine blades and vanes in aviation and energy plants.
• Condition-based maintenance scheduling for high-temperature engine or industrial components, reducing unnecessary replacements.
• Early detection of protective coating degradation in industrial furnaces, reactors, or boilers.
• Application in any system where metallic components are exposed to cycles of high temperature and oxidative environments (e.g., petrochemical processing, power generation).
• Use in research and materials testing to develop improved high-temperature protective coatings.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables non-destructive, external assessment of protective layer health using magnetism, reducing the need for disassembly or destructive inspection.
• Provides early warning of coating wear or damage before catastrophic failure, enhancing safety and reliability.
• Allows maintenance to be scheduled based on actual wear and exposure rather than fixed intervals, potentially lowering maintenance costs and downtime.
• Improves overall equipment efficiency and lifespan by preventing sudden, costly breakdowns.
• Offers sensitive, location-specific detection of protective layer deterioration, supporting targeted repairs or upgrades.

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Inventors & Applicants

Patent Abstract

Within the context of the invention, a component for high-temperature use was developed. Said component comprises a metal base material and a non-ferromagnetic protective layer arranged thereon. The protective layer is able to form a protective oxide layer on the component surface at temperatures between 600 °C and 1100 °C. According to the invention, a sensor material is introduced into the protective layer, wherein in the stated temperature range, the local magnetism, in particular ferromagnetism or ferrimagnetism, at the location of the sensor material depends on the local concentration and/or composition of the material of the protective layer in the immediate vicinity of the sensor material and/or on the cumulative temperature-time curve at the location of the sensor material. The component can be externally, nondestructively tested to determine the local magnetism in the protective layer, which is typically between 100 µm and 500 µm thick. In particular in the method for operating a component at high temperature according to the invention, this leads to significantly lower maintenance costs than the prior art.