Strain Measurement System for Operation in Extreme Environments

ABSTRACT: The U.S. Air Force has a critical need for new robust strain sensors capable of accurately measuring the strain of structural components in high temperature harsh environment applications. During Phase I, Environetix will leverage extensive experience in wireless high temperature sensor materials, devices, packaging, and data acquisition, to develop and lab-test a prototype surface acoustic wave (SAW) strain sensor. The technology uses licensed, patented SAW devices fabricated using stable high-temperature films, LGS substrates, and proprietary sensor attachment methodology. Environetix will perform extensive testing and evaluation during Phase I, using numerous first generation prototype sensors to investigate current limits of LGS SAW strain sensor technology, and then develop a next generation prototype LGS SAW sensor design to optimize strain sensitivity, accuracy, and dynamic range. Preliminary sensor packaging will be designed and tested with sensor attachment to candidate high-temperature metals and ceramics. A complete sensor prototype including a LGS SAW strain sensor, sensor packaging, and attachment will be fabricated, and calibration protocols will be developed. Feasibility of Environetix"s LGS SAW strain sensors will be demonstrated by testing in laboratory furnaces up to 1600°F (870°C) to obtain data for sensor performance characteristics including reliability, accuracy, resolution, dynamic range, and response time. BENEFIT: Environetix will adapt the commercialization strategy used for its initial commercially available product, the EVHT-100 Wireless High Temperature Sensor System, to demonstrate, commercialize and deploy a LGS surface-acoustic-wave (SAW) strain sensor system. The strategy involves developing several generations of prototype sensor devices and making them available to the Air Force to validate advanced structural concepts and technologies for hypersonic flight applications. It is anticipated that successful strain sensor technology demonstrations during later stages of Phase II will lead to license agreements between Environetix Technologies Corporation and several key aerospace structure OEMs, turbine engine OEMs. Environetix will deliver initial quantities of sensor systems to the Air Force, and will interact with supply manufacturers to deliver sensors in production-scale quantities to meet USAF needs. The Environetix strain sensor system will provide data that has far-reaching benefits for the USAF including allowing increased thrust-to-weight ratios, decreased fuel consumption and engine validation costs, and material data that could be used by life prediction models for better component health management practices. In addition, OEMs will use this technology for aero-frame, turbine engine and material development, since it provides sensing data not yet available to the industry. The importance of this enabling technology goes beyond DoD applications, and will quickly find its way into the commercial aerospace industry, turbine engine testing industry, power industry, and several industrial control processes that operate in harsh environment conditions.