Embedded Sensors in Turbine Systems by Direct Write Thermal Spray Technology

70364 Monitoring the performance of high temperature components in advanced gas turbine engines will be required in order to accelerate the insertion of advanced materials, coatings, and novel designs. For example, by continuously collecting component temperature and strain information, one can provide feedback on the efficiency and performance of the engine as well as the health of engineering components. Embedded sensors could achieve this requirement; however, the incorporation of sensors within harsh turbine environments represents a challenging task. Issues concerning sensor location and integration, sensor performance, robustness and reproducibility must be addressed. In addition, the extraction of signals in harsh environments requires complex lead wire attachments that are currently performed manually with considerable variation and error. This project will develop embedded sensors within protective coatings. The sensors will be robust and reproducible and applicable for harsh environments. Phase I will design, fabricate, and characterize the sensors, and assess their performance through static (furnace) and dynamic (flame impingement) tests. A system-level design will incorporate the sensors within thermal barriers and other coatings used in turbines. Two sensor systems will be built and demonstrated: (1) a K-type thermocouple capable of measuring component temperatures up to 1300oC, and (2) a strain gauge capable of temperatures up to 1200oC. Sensor performance will be assessed with respect to design criteria, survivability, and behavior of the integrated component/coating. Commercial Applications and Other Benefits as described by the awardee: The technology should provide in-situ monitoring of the performance of industrial gas turbines and enable failure assessment and condition-based maintenance of engine components (particularly coatings). Other embedded sensor applications include automotive, marine, and diesel engine components