Development of Packaging and Integration of Sensors for On-Line Use in Harsh Environments

A number of sensors and control systems have been developed for use within power systems; however, the effects of high temperature, corrosive/oxidizing atmospheres, and abrasive media have limited their use in ultra-supercritical boilers and steam turbines. The inability to monitor actual components in real time leads to higher operating and maintenance costs and decreases equipment availability, which directly affects the reliability of the U.S. electric supply. Improved sensor packaging and encapsulation is needed to enable on-line sensing for structural health monitoring. This project will develop new sensor packaging concepts that will (1) encapsulate low profile temperature and strain gages with moisture/corrosion barrier coatings, (2) improve lead-wire connections to sensors, and (3) enable robust sensor routing and connections in high temperature oxidizing environments. Commercial Applications and other Benefits as described by the awardee: Steam turbines, gas turbines, and boilers used in the power generation industry are examples of critical equipment that must operate at top performance to provide the low cost electricity that drives the U.S. economy. The packaging technology developed in this project should expand the market for sensors for structural health monitoring of these components. Other applications include commercial and military aviation, aerospace structures, and transportation.