SBIR-STTR Award

The U.S. Navy is interested in the development of non-intrusive, low-profile, conformal-coated sensors on critical components for in-situ measurement of temperature, pressure, and strain on static (e.g., vane) and rotating (e.g., blades, disk, or blisk) components in turbine engines. Ideally these thin-film sensors would operate and survive in the harsh operating environments of the engine, which induces vibration, thermal-cycling, oxidation, corrosion, and sand-erosion conditions. Engineered Coatings, Inc. (ECI) with our team member Southwest Research Institute (SwRI), propose to demonstrate an enhanced plasma deposition method to deposit a nanostructured multilayer (ML) ceramic sensor/dielectric coating system for temperature measurement under high heat-flux conditions. Initially the ML sensor system will be deposited onto Ni-alloy coupons for measurement of adhesion/toughness, residual stress, and thermal cycling / oxidation resistance to verify ML integrity. A preliminary Materials and Process specification will be developed for the best deposition parameters and materials. A cost/benefit analysis and technology integration plan will be developed. In the Option effort, SwRI will demonstrate their shadow-mask patterning technique to deposit thin-film ceramic sensor traces for thermoelectric voltage measurements. In addition, patterning of a complex-curvature component (e.g., engine blade) with the thin-film sensor will be demonstrated in the Option Program.

Benefit:
Development of survivable low-profile thin-film sensors will enable the more reliable measurement of operating conditions inside turbine engines. More reliable data is useful for verification/validation of life-prediction models and testing of new engine designs and better scheduling of maintenance operations. Industry applications include engine monitoring for commercial airlines, non-intrusive monitoring of high-temperature materials fabrication processes, and monitoring of process variables in the energy generation industry.

Keywords:
complex-curvature, complex-curvature, thermoelectric-voltage, shadow-mask, adhesion, enhanced-plasma-processing, thermal-cycling, Ceramic-thermocouple

The U.S. Navy desires non-intrusive, conformally-coated sensors on stationary and rotating turbine-engine components to measure temperature, pressure, and strain. These thin-film sensors must be durable to survive the harsh engine operating environment (vibration, thermal-cycling/oxidation). Engineered Coatings, Inc. (ECI) and Southwest Research Institute (SwRI), propose to continue our work in Phase I to initially optimize the substrate and deposition conditions to achieve high-quality, low-defect alumina dielectric. Next, we will deposit nanostructured nitride and noble-metal thermocouple sensor legs using shadow-masking. The multilayer (ML) sensor will be finished with an encapsulating layer of alumina and topped with an erosion and corrosion-resistant protective layer. This ML sensor system will also be demonstrated on a curved blade using conforming shadow masks. Characterization will include microstructure, thermoelectric performance, and survival to thermal cycling/oxidation. Finally, the sensor system will be tested in a burner or engine rig to simulate the thermo-mechanical environment of turbine engine operation. In the Phase II option, we will demonstrate the reproducibility of sensor fabrication on curved blade surfaces and expose coated-blades in the burner or engine rig. A preliminary Materials and Process specification will be updated for the best deposition parameters and materials and a technology integration plan will be developed.

Benefit:
Non-intrusive sensors will be valuable for engine designers/developers to validate models and provide information for future engine design. In addition, performance measurements during operation can be used for health monitoring and maintenance scheduling. Low-profile sensors can be integrated with thermal protection systems of aerospace vehicles to monitor temperatures during flight trajectories. Application of thin-film sensors to cutting tools will enable measurement of cutting tool temperatures and stress/strain, which can be used to adjust machining parameters.

Keywords:
sputter-deposition, thin-film-thermocouples, Ceramics, protective-coatings, shadow-mask, High-temperature