coatings

Article
Non-Destructive Evaluation of Coating Thickness Using Water
Immersion Ultrasonic Testing
Jiannan Zhang 1 , Younho Cho 2, * , Jeongnam Kim 1 , Azamatjon Kakhramon ugli Malikov 1 , Young H. Kim 3 ,
Jin-Hak Yi 4 and Weibin Li 5

1 Graduate School of Mechanical System Design, Pusan National University, Busan 46241, Korea;
[email protected] (J.Z.); [email protected] (J.K.); [email protected] (A.K.u.M.)
2 School of Mechanical Engineering, Pusan National University, Busan 46241, Korea
3 Institute of Nuclear Safety and Management, Pusan National University, Busan 46241, Korea;
[email protected]
4 Coastal Development and Ocean Energy Research Center, Korean Institute of Ocean Science & Technology,
Busan 49111, Korea; [email protected]
5 School of Aerospace Engineering, Xiamen University, Xiamen 361102, China; [email protected]
* Correspondence: [email protected]; Tel.: +82-51-510-2323

Abstract: The coating is applied to prevent corrosion on the surface of ships or marine structures,
and the thickness of the coating affects its anti-corrosion effect. As a result, non-destructive testing
(NDT) is required to measure coating thickness, and ultrasonic NDT is a convenient and quick way
to measure the thickness of underwater coatings. However, the offshore coating’s energy attenuation
and absorption rates are high, the ultrasonic pulse echo test is difficult, and the testing environment
is harsh. Because of the coating’s high attenuation, the distance of the optimal water delay line



designed based on the reflection coefficient of the vertically incident wave is used. To accurately


measure the thickness of the coating material, TOF of the reflected echo on the time-domain waveform
Citation: Zhang, J.; Cho, Y.; Kim, J.; was evaluated. The experimental results show that, when compared to caliper measurements, the
Malikov, A.K.u.; Kim, Y.H.; Yi, J.-H.;
coating thickness measured by the proposed method has a lower error and can be used for accurate
Li, W. Non-Destructive Evaluation of
measurement. The use of ultrasonic water immersion measurement is almost limitless in terms of
Coating Thickness Using Water
size, location, and material of the object to be measured, and it is expected to be used to measure the
Immersion Ultrasonic Testing.
Coatings 2021, 11, 1421. https://
thickness of the surface coating of ships or marine structures in the water.
doi.org/10.3390/coatings11111421
Keywords: non-destructive testing (NDT); ultrasonic pulse-echo; ultrasonic immersion measurement
Academic Editor: Joe Sakai

Received: 27 October 2021

Accepted: 16 November 2021 1. Introduction
Published: 20 November 2021 Coatings are widely used as anti-corrosion layers in ships or marine structures [1].
When the thickness of the coating and its uniformity directly affect the anti-corrosion
Publisher’s Note: MDPI stays neutral effect [2], it may cause safety problems for ships or marine structures, and ultimately lead
with regard to jurisdictional claims in to accidents. The life of the coating structure is directly related to the thickness in the
published maps and institutional affil-
coating material. Therefore, it is very important that the thickness in the coating must
iations.
be monitored regularly, but in practical applications, the coating is obviously thinner,
especially on the surface of marine structures [3]. For example, when the coating material
of a ship is applied to the surface of a metal structure, the thickness of the coating material
can be even thinner, which increases the difficulty of the assessment of coating thickness.
Copyright: © 2021 by the authors. Non-Destructive Testing (NDT) is an effective method for assessing the structural
Licensee MDPI, Basel, Switzerland. integrity of these and identifying any thickness degradation, deviations or defects [4]. Ap-
This article is an open access article propriate non-destructive testing techniques need to accurately detect, locate, and measure
distributed under the terms and
structural parameters, such as thickness and defects, in a non-invasive manner, and use the
conditions of the Creative Commons
results to plan wisely for future use and maintenance. In order to deal with these situations,
Attribution (CC BY) license (https://
many researchers and engineers have developed many new NDT technologies, such as
creativecommons.org/licenses/by/
ultrasonic (UT) techniques, radiograph (RT), magnetic flux leakage (MT), electromechanical
4.0/).

Coatings 2021, 11, 1421. https://doi.org/10.3390/coatings11111421 https://www.mdpi.com/journal/coatings

Coatings 2021, 11, 1421 2 of 11

impedance (EMI) techniques and eddy current (ET) technology. Among them, EMI is very
effective in the structural health monitoring of bolted structures [5,6]. The fundamental part
of the method is to utilize electromechanical (EM) impedance responses as local dynamic
features for assessing the structural damage. UT has been widely used in many fields such
as cleaning, medical treatment [7] and ultrasonic measurement in the engineering field, for
structural non-destructive testing, medical diagnosis and sonar. The existing ultrasonic
nondestructive testing methods for coating thickness mainly include ultrasonic microscope
technology, ultrasonic surface wave technology and so forth, but these technologies require
high testing conditions, and the system and operation are complicated, and the equipment
cost is high. So, they are not suitable for application to ultrasonic water immersion coating
thickness determination. The Polytec 45MG system, based on the B-scan (back reflection)
technique, can measure thicknesses ranging from 1.25 up to 19 mm [8]. Ultrasonic bulk
wave technology has its unique advantages in detecting local thickness and defects point
by point [9]. However, when applied to ships or marine structures, the technology also
has certain shortcomings due to environmental influences, such as time-consuming local
measurement and limited accessibility. These shortcomings lead to a reduction in efficiency
and an increase in cost. Therefore, there is an urgent need for a new non-destructive testing
method: ultrasonic water immersion measurement.
The pulse receiver is used to generate and receive ultrasound. A pulse is applied to
the short electric pulse on the piezoelectric element in the ultrasonic transducer to make it
vibrate and generate sound waves. We call it the Excitation Pulse, also known informally
as the “main bang”. However, the main bang area shows that the pulse-echo test method
cannot detect fast-returning echoes [10]. If the propagation time is short, the reflected
echoes are superimposed or buried in the “main bang” [11]. When the pulse duration is
short, a transducer with a higher center frequency can be used to solve the problem of
echo overlap [12]. On the other hand, the high-frequency energy decays faster, and the
coating thickness with strong attenuation cannot be evaluated [13]. Ultrasonic pulse echo
testing requires the time-of-flight (TOF) of the echo reflected from the coating boundary.
However, the back wall echoes of the coating are very close to each other, so it is a key issue
to accurately estimate the TOF of the echo signal. Wavelet analysis is based on cognitive
estimation using Morlet wavelet and least mean square (LMS) [14], the edited least squares
(LS) method based on modified Gauss Newton (MGN) [15], based on the use of Hilbert
transform between the two signals [16], and the central ellipse algorithm [17].
In this paper, ultrasonic water immersion body wave technology is used to detect
coating thickness [18]. In the process of using ultrasonic sensor equipment to calculate the
thickness of each propagation medium, reflection is caused at the interface of the medium
or at the end of the material [19], and the thickness of each reflected wave can be calculated
through the TOF of each reflected wave. However, in the direct pulse echo measurement
of the coating material of the sample, the result was not as good as we expected. When
the ultrasonic velocity is high or the sample thickness is thin, the echo signal is very close
to the “master bang” of the transmitted signal. The flight time is shortened, and the two
echoes overlap, which reduces the accuracy of the measurement. In order to overcome
this phenomenon, a delay line is used. In the previous studies, we implement the acrylic
delay line; the experiment was carried out in the air [20] but coatings in water also require
accurate thickness measurements, which cannot be done in air. So, in this research, we
conducted the water immersion test and measured the thickness under the water. Therefore,
a similar method is used in this article. After calculating the optimal distance of the water
delay line between the coating material in the water and the immersion transducer, an
experiment is performed to select the optimal distance.

2. Ultrasonic Echo Signal Theory of Delay Line

In the direct pulse echo measurement of the specimen coating material, the result was
not as good as we expected. The main reason for this is that the coating of the test piece was
too thin. The average thickness of building materials is about 2 mm. When the thickness
Coatings 2021, 11, 1421 3 of 11

is reduced, the echo is located very close to the base material of the specimen, and the
waveforms are mixed. When the ultrasonic speed is high or the specimen thickness is thin,
the echo signal is very close to the “main bang” transmission signal. In addition, the flight
time is shortened. This phenomenon causes the two echoes to overlap, which reduces the
accuracy of the measurement. In order to overcome this phenomenon, a delay line is used.
The ultrasonic delay line is a layer of material used to temporarily and accurately
delay the echo signal to isolate it from the transmission signal. The characteristics of the
material used for the delay line are the basic factors that need to be considered. It can
be quartz, acrylic and aluminum, and even water can be used as the material for the
delay line. The amplitude of the reflected signal is related to the incident factor of the
normal beam. The acoustic impedance value is directly related to the reflection coefficient
and the transmission coefficient. The transmission coefficient equation and the reflection
coefficient equation can be obtained from the stress balance equation at the boundary of
the two solids.
When the harmonics propagating in the vertical x direction of the emitted ultrasonic
wave reach the interface of the two media, the plane wave incident on the interface of the
two materials is divided into two parts: part of the energy passes through the interface,
and the other is reflected back. Therefore, the elastic field is independent of the horizontal
y direction, so all the differentials about the y direction in the equation of motion are zero.
The incident waveform equation as:

(I)
u x = Iei(k1 x−ωt) ; (1)

in this case, the displacement of the reflected field can be written as:

( R)
ux = A R e−i(k1 x+ωt) , (2)

then k1 = ω/CL1 and k2 = ω/CL2

At the boundary between the two media, boundary conditions must be met. For the
entire elastic field of the first medium and another medium, there are:
(I) ( R)
u1 = u x + u x = Iei(k1 x−ωt) + A R e−i(k1 x+ωt)
(T ) (3)
u2 = u x = A T e−i(k2 x+ωt)

for the one-dimensional case, the generalized Hooke’ s law is:

∂u
σx = (λ + 2µ) , σxy = 0 (4)
∂x
the reflection coefficient obtained from the solution of some equations is as follows:

Z2 − Z1
R= . (5)
Z1 + Z2

The ultrasonic wave is reflected at the boundary where the acoustic impedance Z
of the materials on both sides of the interface is different. This difference in Z is often
referred to as impedance mismatch. The greater the impedance mismatch, the greater the
percentage of energy reflected at the boundary or the boundary between one medium and
another medium.
Since particle velocity and local particle pressure must be continuous at the bound-
ary, the fraction of reflected incident wave intensity can be derived. When the acoustic
impedance of the materials on both sides of the boundary is known, the fraction of reflected
incident wave intensity can be calculated by the following formula. The resulting value
is called the reflection coefficient. Multiply the reflection coefficient by 100 to obtain the
reflected energy as a percentage of the original energy.
Coatings 2021, 11, x FOR PEER REVIEW 4 of 11
Coatings 2021, 11, 1421 4 of 11

Since the reflected and transmitted energy must be equal to the total amount of inci-
Since the
dent energy, thereflected and transmitted
transmission coefficient must energy must be equal
be calculated simplytobythe total amount
subtracting of
the re-
incident energy, the transmission coefficient must be calculated simply by subtracting the
flection coefficient from the first medium. Therefore, the transmission coefficient can be
reflection coefficient from the first medium. Therefore, the transmission coefficient can be
written as:
written as:
2Z2
T= = . (6)
Z1 + Z2
Regarding
Regardingthe theoptimal
optimalthickness
thicknessofof thethedelay
delay line, apply
line, applya delay lineline
a delay on the top top
on the of the
of
specimen
the specimen to propagate the initial signal source to the specimen through the delayline.
to propagate the initial signal source to the specimen through the delay line.
However,
However,at at the
the boundary
boundary between
betweenthe thedelay
delayline
line and
and thethe specimen,
specimen, partpart of
of the
the signal
signal is
is
reflected
reflectedback,
back, andand the
the remaining
remaining part part of
of the
the signal
signal is is transmitted
transmitted to to the specimen.
specimen. TheThe
DL-1
DL-1signal
signalisisthe
thereflected
reflectedsignal
signal(Figure
(Figure1).1).Part
Partofofthe
theultrasonic
ultrasonicsignal
signalpropagating
propagatingfromfrom
the
thedelay
delayline
linetotothe
thespecimen
specimenisisreflected
reflected from
from the
the base
base material
material of
of the
the specimen.
specimen. PartPart of
of
the echo is transmitted to the specimen and arrives at the receiver
the echo is transmitted to the specimen and arrives at the receiver as a waveform. Not as a waveform. Not all
ultrasonic signals
all ultrasonic propagate
signals fromfrom
propagate the specimen
the specimento theto delay line, and
the delay theand
line, remaining wave-
the remaining
forms continue
waveforms to be reflected
continue in thein
to be reflected specimen.
the specimen.

Figure
Figure 1.
1. Schematic
Schematicdiagram
diagramusing
using delay
delay line.
line.

Theconventional
The conventionaldelaydelayline
line design
design method
method is is when
when thethe measurement
measurement signal
signal of spec-
speci-
men C-1
imen C-1 reaches
reachesbetween
betweenthe thefirst
firstecho
echosignal
signalDL-1
DL-1 and
andthethe
second
secondecho signal
echo DL-2
signal of the
DL-2 of
delay
the line.line.
delay As As
shown
shownin the figure,
in the S0 isS0the
figure, is signal in the
the signal in“main bang”,
the “main Tdl is the is
bang”, time
thewhen
time
the ultrasonic
when wavewave
the ultrasonic returns on the
returns onsurface of the
the surface of delay line,line,
the delay TA is the
andand timetime
is the when
when the
ultrasonic wave is sent from S0 to the surface of the coating. The range
the ultrasonic wave is sent from S0 to the surface of the coating. The range between DL-1 between DL-1 and
DL-2
and signals
DL-2 defines
signals the arrival
defines timetime
the arrival limitlimit
of theof measurement
the measurement signal as: as:
signal

Tdl + T+dl −1 ≤ ≤
TA ≤≤2T
2dl −−Tdl −2 . . (7)
By replacing the acoustic
By replacing path,path,
the acoustic the maximum
the maximum and minimum
and minimum specimen thickness
specimen range
thickness for
range
afor
given delay line geometry can
a given delay line geometry be determined
can be ∗determined as follows:
as follows:
2∗ 2 2∗
+ = +
2∗ Lc min
Vc + 2∗VLdldl = 2∗VLdldl + Tdl −1
∗ ∗ ∗ 2∗ Lc min 2∗ Ldl 2∗ Ldl
(8)
+ = − Vc . + V = V − Tc−1 . dl dl

The theory is applied in the experiment. The thickness of the coating used in the
The theory is applied in the experiment. The thickness of the coating used in the ex-
experiment is 2.13 mm. The coating is glued to a 4 mm thick carbon steel base material
periment is 2.13 mm,. The coating is glued to a 4 mm thick carbon steel base material
and the propagation speed of ultrasonic waves in water is 1.48 mm/µs. By experimental
and the propagation speed of ultrasonic waves in water is 1.48 mm⁄μs. By experimental
measurement, the propagation speed of ultrasonic waves in the coating is 2.44 mm/µs. In
measurement, the propagation speed of ultrasonic waves in the coating is 2.44 mm⁄μs.
order to clearly analyze the water delay line signal and the coating signal, the optimal size
In order to clearly analyze the water delay line signal and the coating signal, the optimal
of the delay line can be calculated by the following formula:
size of the delay line can be calculated by the following formula:
V 1.48. mm/s
⁄
Ldl mid = 2L=c 2dl = 2=
×22.13
× 2.13
mmmm
× × . ⁄
=
= 2.6
2.6 mm.
mm. (9)
VC 2.44 mm/s
This section describes the measurement of coating thickness using ultrasonic waves
This section describes the measurement of coating thickness using ultrasonic waves
in water. It is deduced by theory that, when water is used as the delay line, the optimal
in water. It is deduced by theory that, when water is used as the delay line, the optimal
Coatings 2021, 11, 1421 5 of 11

distance of the delay line is 2.6 mm. The TOF of the peak or trough of the ultrasonic signal
of the water delay line determines the coating thickness. In order to ensure the accuracy of
the theory, the delay line distances of 2, 2.6, 5 and 10 mm, were tested on the two regions.
At the same time, in order to reduce the error of the experiment, the delay lines of different
distances were measured four times and ensured. The same conditions were set again in
each experiment.

3. Experiment
3.1. Ultrasonic Signal from the Coating Layer
In order to prevent the reflected echo from being superimposed or buried in the
main bang, the ultrasonic delay line is required to move the first echo in the main bang.
Figure 1 shows the ultrasonic signal propagation mode when using a delay line, where
DL-1 and DL-2 represent the first signal echo and the second signal echo reflected between
the delay line and the coating, and C-1 and C-2 represent the first signal echo and the
second signal echo reflected from the back wall of the coating. Part of the ultrasonic energy
will propagate into the base material. B represents the echo reflected from the back wall of
the base material.

3.2. Preparation of Test Specimen

In order to verify the proposed method, test specimens were prepared. The coating
material was manufactured according to the manufacturer’ s description. The coating
material was composed of epoxy resin Alocit 28.14 and hardener (see Table 1 for details of
the coating material) [21]. A carbon steel plate with a size of 150 mm × 50 mm × 4 mm
was used as the base material to prepare the specimen.

Table 1. Information/Material Properties of the coating materials.

Product Alocit 28.14

manufacturer Alocit Systems
Density 1.7 g/m3
Mixing weight ratio
5:1
(Alocit 28.14: hardener)

There are many coating methods, but the commonly used method in this field is to use
a traditional roller to coat the surface of the substrate alone [22]. Due to manual mixing and
roller coating, the coating may be thin on the four sides of the substrate or uneven in certain
areas. In order to make the experimental results more accurate, the coating was divided
into 9 × 3 areas. The thickness of each area was measured with a caliper, and the ultrasonic
velocity of each area was measured with a transducer. The two experimental areas with the
closest thickness and ultrasonic velocity were screened out, that is, the coating thickness
of the two experimental areas was 2.13 mm, and the ultrasonic velocity was 2.44 mm/µs.
The purpose is to make the final experimental results more accurate through the controlled
variable method. Finally, two almost identical thickness areas (20th area and 21st area)
were screened out for ultrasonic water immersion measurement, shown in Figure 2. The
water immersion transducer was fixed vertically above the measuring area of the coating in
the water with an instrument; the distance from the surface of the transducer to the surface
of the coating was the distance of the water delay line.
ngs 2021, 11, x FOR PEER REVIEW 6 of 11
Coatings 2021, 11, 1421 6 of 11
Coatings 2021, 11, x FOR PEER REVIEW 6 of 11

Figure 2. Optimal suitable area for experimentation was selected from the manufacturing specimen
of the coating:Figure
20th and
Figure 21st.
2.2.Optimal
Optimal suitablearea
suitable areafor
forexperimentation
experimentationwas
wasselected
selectedfrom
fromthe
themanufacturing
manufacturingspecimen
specimen
ofthe
of thecoating:
coating:20th
20thand
and21st.
21st.
3.3. Experimental Setting
Figure 33.3.
3.3. Experimental
Experimental
shows Setting
Settingsetup for the ultrasonic pulse echo measurement of
the instrument
Figure
the specimen. In order 3 shows
obtainthe
Figureto3 shows theinstrument
signal, the setup
instrument setupfor forthe
pulser-receiver theultrasonic
(5072 PR,
ultrasonic pulse echo
echomeasurement
Panametrics,
pulse measurementof of
Waltham, MA, the specimen.
theUSA) In order
was applied toto
specimen. to obtain
theobtain the
underwater signal,
the signal, the
coating pulser-receiver
the specimen (5072
to generate
pulser-receiver (5072 PR,PR,
andPanametrics,
Panametrics,
Waltham,
receive ultrasonic waves.
Waltham, MA,The
MA, USA) was
digital
USA) was applied
appliedto
oscilloscope the
theunderwater
to(WaveRunner
underwater 604coating specimen
Zi, Teledyne
coating specimen to
LeCroy,togenerate
generateand and
receive
Chestnut Ridge, NY,ultrasonic
receive USA) waswaves.
ultrasonic used
waves. toThe
record
The digital
and oscilloscope
digital save the received
oscilloscope (WaveRunner
waveform.
(WaveRunner 604
604The Zi, Teledyne
Teledyne LeCroy,
Zi,center LeCroy,
frequency ofChestnut Ridge,
Ridge,NY,
the piezoelectric
Chestnut USA)
USA)was
immersion
NY, used
usedto
transducer
was torecord
used and
record in
and save
the the
thereceived
experiments
save received is waveform.
3.5 MHz, The
waveform. Thecenter
center
the transducerfrequency of
has a spherical
frequency the piezoelectric
focusing probe
of the piezoelectric immersion
to generate
immersion transducer
a focused
transducer used
used in
sound the experiments
in thebeam, which is 3.5
experiments is 3.5 MHz,
MHz,
the
uses diffraction transducer
theto focus the has
transducer has aaspherical
ultrasonic bulk focusing
spherical wave to aprobe
focusing certain
probe to generate
toposition,
generateso aafocused
the sensing
focused sound
areabeam,
sound beam,which
which
uses
of the transducer diffraction
usescan to
tofocus
focusthe
be approximately
diffraction the ultrasonic
regarded
ultrasonic as bulk
abulk wave
point.wave to
toaacertain
A lower frequency
certain position, so
sothe
transducer
position, thesensing
sensingarea
area
of the
generated long-lasting transducer can
signals can
of the transducer be approximately
thatbeled regarded
to the overlapping
approximately regarded as
of the a point.
as aecho
point. A
waves lower
A lower frequency
whereas, at transducer
frequency transducer
generated
high frequencies, long-lasting
the amplitude
generated long-lasting signals
ratiosignals that led
was increased.
that led toto the
Intheorderoverlapping
to determine
overlapping ofofthe
theecho
the echowaves
best waves
exci- whereas,
whereas, at
at high
tation conditions,
high the frequencies,
piezoelectric
frequencies, the amplitude
transducerratio
the amplitude ratio
arraywas was
must increased.
determine
increased. In
In the
order order to
feasibility determine
to determine the best
of thethe best exci-
most suitableexcitation conditions,
modeconditions,
tation in advance. the the piezoelectric
piezoelectric transducer
transducer arrayarray
must must determine
determine thethe feasibility
feasibility of
of the
the most suitable mode
most suitable mode in advance. in advance.

Figure 3. Experimental
Figure 3. Experimental setup: (1)(2)
setup: (1) Computer; Computer; (2) Lecroy oscilloscope;
Lecroy oscilloscope; (3) Pulser
(3) Pulser receiver; (4)receiver; (4) Piezo
Piezo electric immersion
electric immersion transducer;
Figure 3. (5) Specimen
Experimental setup:and
(1) (6) Water tank.
Computer; (2) Lecroy oscilloscope; (3) Pulser receiver; (4) Piezo
transducer; (5) Specimen and (6) Water tank.
electric immersion transducer; (5) Specimen and (6) Water tank.
The experiment
Thewas divided into
experiment wasthree steps.
divided Thethree
into first step was
steps. Theto evaluate
first stepthe thick-
was to evaluate the
ness of the coating with
thickness
The of four delay
the coating
experiment lines
was with with
fourdifferent
divided delay
into distances
lines
three with
steps. onfirst
thestep
different
The 20th area
toof
distances
was thethe 20th
on
evaluate area
the thick-
coating. Theofsecond
ness stepcoating
theofcoating.
the was
Thetowith
evaluate
second
four thewas
step
delay thickness
lines withofdifferent
to evaluate the
thecoating using
thickness
distancesof on same
thethe
coating using
20th area ofthe
the
coating. The second step was to evaluate the thickness of the coating using the same
Coatings 2021, 11, x FOR PEER REVIEW 7 of 11
Coatings 2021, 11, 1421 7 of 11

method on the 21st area of the coating, which was to compare different areas under the
same
same method
method to onevaluate
the 21st whether
area of the there was awhich
coating, difference
was toin compare
thickness.different
In the first
areas and sec-
under
ond
the steps
same of the experiment,
method to evaluate wewhether
used a mechanical
there was rod to fix the in
a difference transducer.
thickness.The Inmechan-
the first
ical
androd can keep
second stepsthe coating
of the in the water
experiment, tankavertical,
we used mechanical and the
rod required
to fix thewater delay line
transducer. The
distance
mechanicalcan rod
be setcanbykeep
adjusting the height
the coating of water
in the the mechanical rod. To
tank vertical, andmeasure the coating
the required water
thickness
delay lineindistance
this area, four
can bedifferent points were
set by adjusting selected
the height ofinthe
this area and the
mechanical rod.average value
To measure
the coating
was thickness
taken. Because each in scan
this area, fourscan
can only different
an area points were
of about selected
one in this
point, the area and
measured the
value
average
of value was
the thickness taken. Because
corresponds each scan
to the average canIfonly
value. scan an
the entire area
area of about
needed to beone point,
scanned,
the measured
multi-point value of
scanning was theperformed
thickness according
corresponds to the
to the averageof
immersion value. If the entire
the sample. The num-area
needed
ber to be scanned
of points scanned, increased
multi-point asscanning
the requiredwas accuracy
performed according
increases. to the
The thirdimmersion
was to use of
the sample.
acrylic delay The
line number
evaluation of points scanned
to estimate increased
the coating as the required
thickness accuracy
in two areas increases.
in a non-water
The third was
immersion to use acrylic
environment, thisdelay
was to line evaluation
compare to estimateinthe
the difference thecoating
evaluationthickness in two
thickness of
areas in a non-water immersion
the same area under different methods. environment, this was to compare the difference in the
evaluation thickness of the same area under different methods.
4. Results and Discussion
4. Results and Discussion
The first step was to use ultrasound to check the distance of the water delay line in
Thearea
the 20th firstand
stepmeasure
was to use theultrasound
thickness oftothe check the distance
coating. Figure 4ofshows
the water delay line in
the experimental
the 20th area and measure the thickness of the coating. Figure 4 shows
results of the direct pulse echo test of the water delay line at different distances in the
the experimental
results of the direct pulse echo test of the water delay line at different distances in the
Alocit 28.14 20th area.
Alocit 28.14 20th area.

Figure 4.
Figure Experiment results.
4. Experiment results. The
The20th
20tharea
areacoating
coatingmaterial
materialthickness measured:
thickness (a) (a)
measured: Water delay
Water line line
delay 2 mm, (b) Water
2 mm, delay
(b) Water
line 2.6 mm, (c) Water delay line 5 mm, and (d) Water delay line 10 mm.
delay line 2.6 mm, (c) Water delay line 5 mm, and (d) Water delay line 10 mm
The amplitude change can be observed in the figure, where the first echo represented
The amplitude
by DL-1 is the signal change can be
reflected byobserved in thebetween
the boundary figure, where the first
the delay lineecho
andrepresented
the coating
by DL-1 and
surface, is thethen
signal reflected
DL-2 by the
represents theboundary
second echobetween
of thisthe delayThe
signal. lineecho
and represented
the coating
by C-1 isand
surface, thethen
signal reflected
DL-2 by the
represents theboundary
second echobetween
of thisthe base The
signal. material
echo and the coating
represented by
material,
C-1 and then
is the signal C-2 represents
reflected the second
by the boundary echo ofthe
between this
basesignal, shown
material andinthe
Figure 4. ma-
coating
terial,Table 2 listsC-2
and then therepresents
TOF and thethemeasured
second echo coating thickness
of this in the Alocit
signal, shown in Figure28.14
4. 20th area.
At the junction
Table 2 listsbetween
the TOFthe water
and and the coating,
the measured coatingpart of the ultrasonic
thickness wave
in the Alocit is transmitted
28.14 20th area.
from
At thethe waterbetween
junction to the inside of theand
the water coating, and thepart
the coating, restofisthe
reflected backwave
ultrasonic to theisultrasonic
transmit-
transducer (Echo DL-1). The ultrasonic wave transmitted inside the coating reaches the
surface of the base material and then returns to the ultrasonic transducer (Echo C-1).
Coatings 2021, 11, 1421 8 of 11

Table 2. TOF time difference in 20 areas and coating thickness measurement results.

The Experimental TOF (µs) Coating

∆TOF (µs)
Result of the 20th Area Echo DL-1 Echo C-1 Thickness

2.0 (Water) 3.86 5.59 1.75 2.108

2.6 (Water) 4.88 6.62 1.74 2.123
5.0 (Water) 7.92 9.69 1.77 2.155
10 (Water) 14.76 16.48 1.72 2.098

This measurement method was repeated four times to calculate the average value
of the measured coating thickness for each delay line. Therefore, the coating thicknesses
measured by experiments of (a), (b), (c) and (d) was estimated to be 2.143, 2.137, 2.153, and
2.143 mm.
A caliper was used to manually measure and verify the ultrasonic measurement data.
The thickness calculation error measured by each method is shown in Table 2. The results
show that, although the four experiments can measure the coating thickness with an error
of less than 1%, the thickness error measured by the best delay line theory is the smallest,
which is only one-third to two-halves of the error of the other three experimental results.
The thickness error measured by the experiment is shown in Table 3.

Table 3. Coating thickness measurements by caliper and ultrasound at 20th area.

Distance of the Thickness Measured (mm)

Error
Delay Line L (mm) by Ultrasound by Caliper
The Experimental 2.0 (Water) 2.143 0.622%
Result of the 20th Area 2.6 (Water) 2.137 0.313%
5.0 (Water) 2.153 2.13 1.080%
10 (Water) 2.1427 0.599%
6.2 (Acrylic) 2.12 0.34%

It can be seen that the experimental results are similar in theory. The coating thickness
measured at the distance of the water delay line of 2.6 mm is more accurate, and the
waveform diagram is also very clear and easy to analyze.
The second step was to use ultrasound to check the distance of the water delay line
in the 21st area and measure the thickness of the coating, and the experiment was set up
under the same conditions as the first step, and the coating thickness was measured by the
ultrasonic experiment, shown in Figure 5. A caliper was used to manually measure and
Coatings 2021, 11, x FOR PEER REVIEW 9 of 11
verify the measurement data. The thickness error measured by the experiment is shown in
Table 4.

Figure 5. Experiment
Experiment results.
results. The
The21st
21starea
areacoating
coatingmaterial
materialthickness
thicknessmeasured:
measured:Water
Waterdelay
delayline
line
2.6 mm
2.6 mm.

The third experiment was carried out using acrylic delay lines in the 20th and 21st
areas. Perform the same method as the water immersion ultrasonic measurement, and the
collected signal is shown in Figure 6. The result of calculating the thickness of the coating
material using the information confirmed in the two figures is 2.12 mm, and the result of
Coatings 2021, 11, 1421 9 of 11

Table 4. Coating thickness measurements by caliper and ultrasound at 21st area.

Coatings 2021, 11, x FOR PEER REVIEW 9 of 11

Distance of the Thickness Measured (mm)

Error
Delay Line L (mm) by Ultrasound by Caliper
The Experimental 2.0 (Water) 2.111 0.911%
Result of the 21st Area 2.6 (Water) 2.126 0.195%
5.0 (Water) 2.141 2.13 0.521%
10 (Water) 2.123 0.338%
6.2 (Acrylic) 2.12 0.34%

Although in experiment (d) the experimental results are more accurate than experi-
ments (a) and (c), the measured results are similar to those of experiment b, and the error
is small, but in the waveform diagram, the 10 mm waveform is too fuzzy and difficult to
analyze. So, 2.6 mm is the optimal delay line length. Figure 5 shows the signal measured at
a water delay line distance of 2.6 mm. The TOF of the first echo is 4.985 µs, the arrival time
of the next echo is 6.64 µs, and the thickness is calculated as 2.126 mm. Four measurements
Figure
were 5. Experiment
performed results.
on each Thedelay
of the 21st area coating
lines material
of different thicknessinmeasured:
distances Water delay
the two regions, andline
the
2.6 mm
same conditions were reset for each measurement, and the results in the following table
were obtained. Each measurement will estimate the error and measurement uncertainty
The third
and, finally, theexperiment
experimental was carried
results out that,
show usingcompared
acrylic delay
withlines in the 20th
the thickness and the
value, 21st
areas. Perform the same method as the water immersion
error measured with calipers between the two was less than 1.1%. ultrasonic measurement, and the
collected signalexperiment
The third is shown inwas Figure 6. The
carried outresult
usingofacrylic
calculating
delaythe thickness
lines of the
in the 20th andcoating
21st
material
areas. usingthe
Perform thesame
information
methodconfirmed
as the water in immersion
the two figures mm, and the and
is 2.12measurement,
ultrasonic result
theof
comparison
collected with
signal the measured
is shown in Figure value of the
6. The caliper
result is shown in
of calculating theTables 3 and
thickness of 4. The
the result
coating
of the accurate
material using the measurement
informationofconfirmed
the coating thickness
in the with the
two figures acrylic
is 2.12 mm,delay
and thelineresult
was ob-
of
tained in the preliminary research, the purpose of this article is also to
comparison with the measured value of the caliper is shown in Tables 3 and 4. The result of accurately measure
coating
the thickness.
accurate However,
measurement thecoating
of the acrylicthickness
delay line cannot
with measure
the acrylic theline
delay coating thickness
was obtained
inthe
in water, so the water
preliminary delay
research, theline measurement
purpose is required.
of this article is also toThe coatingmeasure
accurately thickness errors
coating
measured However,
thickness. by the two thedelay line
acrylic experiments
delay line cannot aremeasure
similar,theso coating
the feasibility of the
thickness water
in water,
so the water
delay line isdelay line However,
verified. measurement the is required.
signal of theThe coating
water delaythickness errors
line is not measured
as clear as the
by the two
acrylic delaydelay
line.line experiments are similar, so the feasibility of the water delay line is
verified. However, the signal of the water delay line is not as clear as the acrylic delay line.

Figure 6. Experiment results. Measure the thickness of the coating material with acrylic delay lines of 6.2 mm (a) In the 20th
Figure 6. Experiment results. Measure the thickness of the coating material with acrylic delay lines of 6.2 mm (a) In the
area,
20th(b) In (b)
area, the In
21st
thearea.
21st area.
The thickness of the coating was measured by the water delay line and the ACR
Table line,
delay 3. Coating thickness
and the measurements
optimal water delaybyline
caliper and ultrasound
distance measured at by
20ththe
area.
theory was more
accurate. Although water delay of
Distance hasthe
obvious
De- limitations, in practical(mm)
Thickness Measured applications, marine
structures are usually relatively large. Since the thickness of each scan Error
is measured at one
lay Line L (mm) by Ultrasound by Caliper
point, if it is applied to large-area scanning, multipoint scanning is required to improve the
The Experimental 2.0 (Water) 2.143 0.622%
accuracy. However, most marine structures, such as ships, are in the water. The general
Result of the 20th 2.6 (Water) 2.137 0.313%
ultrasonic nondestructive testing method will be limited, as in the third step in this article,
Area
it is difficult for the acrylic delay line to measure the thickness of the coating in1.080%
5.0 (Water) 2.153 2.13 the water,
10 (Water) 2.1427 0.599%
6.2 (Acrylic) 2.12 0.34%
Coatings 2021, 11, 1421 10 of 11

and the removal of marine structures from the water will incur a very high cost. Therefore,
the method has stability and can directly measure the thickness of the surface coating of
marine structures in water, thereby having the advantages of accuracy, high efficiency and
low cost. It is predicted that the thickness measurement of coating materials that require
high precision or samples thinner than this experiment can be carried out. In the follow-up
research, the effect of the frequency on the accuracy of the thickness measurement will
studied. The optimal value of the frequency will be selected in order to accurately measure
the coating thickness even in complex situations, and so that the signal quality in the
water delay line can be as clean and tidy as the acrylic delay line. We tried to develop
the measurement by guided waves in water. Guided waves can scan the coating without
contact on a large scale, and it is expected to increase the efficiency of coating thickness
measurement.

5. Conclusions
In this study, the TOF method of reflected echo was used to measure the thickness of
the coating in water. According to the results, the following conclusions can be obtained:
1. The delay line allows the thickness of the coating in water to be measured using
a single echo from the back wall of the coating. When comparing the ultrasonic
measurement results with the thickness values measured with a caliper, similar
results were found; the thickness value error measured with calipers between the two
was less than 1.1%.
2. According to the comparison of the experimental results of the water delay line and
the acrylic delay line, the thickness of the coating can be measured simply, quickly
and accurately. However, as most ship’s coatings are underwater, using the water
delay line has the advantage of directly measuring the underwater part of the ship’s
coating, saving money, manpower and time.
3. Based on the method proposed in this research, the thickness of the coating can be
easily determined for other types of coating materials in water. It is almost not limited
by the size, location and material of the test object. Further optimization of design
parameters will be carried out in future research.

Author Contributions: Conceptualization, J.Z. and Y.C.; methodology, J.Z. and A.K.u.M.; software,
J.Z. and A.K.u.M.; validation, J.Z. and J.K.; formal analysis, J.Z. and J.K.; investigation, Y.H.K.; re-
sources, J.-H.Y.; data curation, J.Z.; writing—original draft preparation, J.Z. and J.K.; writing—review
and editing, W.L., Y.H.K. and Y.C.; visualization, J.Z.; supervision, Y.C.; project administration,
J.-H.Y.; funding acquisition, J.-H.Y. All authors have read and agreed to the published version of
the manuscript.
Funding: The authors thank the supported by Korea Evaluation Institute of Industrial Technology
(KEIT) grant funded by the Korea government(MOTIE) (No. 10085576). This research was funded by
Korea Institute of Ocean Science and Technology (KIOST), KIOST project number PE99931.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Data is contained within the article.
Conflicts of Interest: The authors declare no conflict of interest.

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