Micro-Scale Additive Manufacturing of Strain Gauges on Non-planar Surface of Jet Engine Blades: Extended Objectives

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This project is an extension to a collaborative project between the University of Waterloo and GE Aviation in which the aim has been to deploy additive manufacturing (AM) to the fabrication of strain gauges on the non-planar surface of jet engine blades. Given the opportunities provided by Micro-Scale Aerosol-Jet AM and also the importance of health monitoring, load detection, and effective strain and vibration measurements in critical aerospace parts, the first phase of the project was proposed resulting in 14 technology disclosures to GE from which 7 might be filed for patent protection. In this extended CRD project, several remaining challenges including a thorough failure analysis, printing process optimization along with temperature compensation methods for low temperature (Ag-based) and high temperature printed gauges (Pd-Cr based) will be conducted. Development of a proper wire soldering procedure for high temperature printed gauges, a new sol-gel method for the creation of insulation layer, and development of a new ink to print gauges that can stand up to 1200°C are other objectives. In addition, thorough static, dynamic and vibration tests on low and high temperature strain gauges on jet engine blades in harsh and high temperature environments will be conducted by the GE team. The benefit of aerosol-jet AM of strain gauges for jet engine blades is tremendous. The printed sensors will be miniaturized compared to commercially available strain sensors that can be mounted on the surface. It is also expected that aerosol-jet AM strain gauges will provide high resolution measurements because their micro-size and high printing resolution will allow a larger sensor density per surface area, thus most likely providing continuous measurement.The outcome of this technology, if successful, will be pervasive and will have a deep and broad impact. Many industries will benefit from more on-demand miniaturized printed strain gauges, with the most immediate example beyond aerospace being the automotive industry, for their integrated passive sensors.