An Integrated Approach to Sensor Materials Synthesis, Design and Fabrication for Extreme Temperature Applications

A new complementary approach is proposed to identify, characterize and integrate high temperature materials into harsh environment diagnostic systems. Program partner URI will sputter candidate conductive oxides with continuously varying levels of doping. Test specimens will be fabricated and systematically assessed using combinatorial synthesis to determine which exhibit the most favorable characteristics e.g., high temperature stability, consistency, sensitivity, for sensor use. MesoScribe Technologies will apply its Mesoplasma Direct Write process, a high-precision derivative of thermal spray technology, to deposit the selected materials in precise sensor architectures. URI's experience in material characterization and ceramic oxide strain gages will be combined with MesoScribe's expertise in sensor design and fabrication to achieve application-specific measurement capability in high temperature (1600C) regime of gas turbines and hypersonic structures. BENEFIT: The capability to monitor the health of aircraft engine components and prognosticate system performance in real-time is required for a number of military aircraft and weapons platforms.   Operating temperatures are being pushed higher requiring the use of highly engineered materials and protective thermal barrier coatings.  The proposed technology will develop and validate new ceramic sensor materials capable of measuring temperatures up to 1600°C.  The use of combinatorial synthesis and Direct Write processing provides a solid foundation for sensor development at an accelerated pace.  Unprecedented sensor capabilities for extreme temperature environments will be demonstrated.  Furthermore, the use of ceramic semi-conducting materials will significantly decrease sensor manufacturing costs compared to the costs associated with precious metals. MesoScribe has developed strategic partnerships with OEMs, Defense Laboratories, and commercial end-users.  Specific applications of interest include gas turbine engine components for aero turbofans and power generation, thermal protection systems, hypersonic engine instrumentation, and aerospace components.