Terahertz Sensor for Non-Contact Thickness and Quality Measurement of Automobile Paints of Varying Complexity

In this paper, we propose to use terahertz pulsed imaging (TPI) as a novel tool to measure the thickness and quality of up to four layers of car paint on both metallic and non-metallic substrates. Using a rigorous one-dimensional electromagnetic model for terahertz propagation in a multi-layered medium combined with a numerical fitting method, the refractive index, extinction coefficient, and thickness of individual paint layers were determined. This proposed method was shown to be able to resolve coating layers down to a thickness of 18 m and was validated for both single-and multi-layer automobile paint samples. Results of the terahertz measurements were benchmarked against other techniques that are currently used for non-destructive testing during car manufacture: ultrasound and eddy current measurements, as well as two reference techniques, X-ray microcomputed tomography and surface profilometry. Good consistency was found between the techniques. Compared to conventional techniques, TPI has the advantage that it is a non-contact method and that it is able to spatially resolve the thickness uniformity distribution information by two-dimensional mapping.