Micro-scale Additive Manufacturing (3D Printing) of High-Temperature Strain Sensors on Non-Planar Surfaces of Jet Engine Components

喷气发动机部件非平面表面高温应变传感器的微型增材制造（3D 打印）

• 批准号: 576693-2022
• 负责人: Toyserkani, EhsanE
• 金额: $ 13.03万
• 依托单位: University of Waterloo
• 依托单位国家: 加拿大
• 项目类别: Alliance Grants
• 财政年份: 2022
• 资助国家: 加拿大
• 起止时间: 2022-01-01 至 2023-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=760395
• 关键词: Micro; scale; Additive; Manufacturing; 3D

This project aims to strengthen a collaborative project between the University of Waterloo (UW) and GE Aviation, in which micro-scale additive manufacturing (AM), known as 3D printing, is deployed to fabricate high-temperature strain gauges on the non-planar surface of jet engine components. Given the opportunities provided by micro-scale aerosol-jet AM and the importance of health monitoring, load detection, and effective strain and vibration measurements in critical aerospace parts, this new phase of the project is proposed to capitalize on the patented technology developed through the previous partnership between GE Aviation and UW to eventually push the technology to a higher Technology Readiness Level of 6. To this end, several objectives are proposed to develop comprehensive recipes for enabling 3D printing of defect-free long tracks via aerosol jet printing of Palladium-Chromium (Pd-Cr) and Alumina inks to meet jet engine requirements. In addition, a Pd-Cr ink with a low-temperature sintering property will be developed to minimize the side effect of high temperature on components. This will be supported by an advanced lead attachment procedure that will be developed based on the reduction of sintering temperature and numerical simulation. In addition, thorough vibration tests on 3D printed gauges on jet engine blades will be conducted in harsh and high-temperature environments by the GE team. The benefit of aerosol-jet AM of strain gauges for jet engine instrumentation is tremendous. The 3D printed sensors will be miniaturized compared to commercially available strain sensors thus offering a platform to minimize a negative impact of sensors on the flow path and part response due to their relatively small size and thickness compared to commercially available sensors. The outcome of this technology will be pervasive and will have a deep and broad impact on many industries (e.g., aerospace, automotive and energy) that will benefit from more on-demand miniaturized 3D printed strain gauges.

该项目旨在加强滑铁卢大学（UW）和GE Aviation之间的协作项目，该项目部署了微型添加剂制造（AM），称为3D打印，用于在喷气发动机组件的非平面表面上制造高温应变仪表。鉴于微尺度的气溶胶喷射AM以及健康监测，负载检测以及在重要航空航天零件的有效应变和振动测量的重要性，该项目的这个新阶段提议利用通过GE Aviation和UW之间的前一个伙伴关系来推动该技术的综合技术，以启动3个目标，以启动几个目标。通过钯金（PD-CR）和氧化铝油墨的气溶胶喷射打印的无缺陷长轨，以满足喷气发动机的需求。此外，将开发具有低温烧结特性的PD-CR墨水，以最大程度地减少高温对组件的副作用。这将由先进的铅固定程序支持，该程序将根据烧结温度和数值模拟的降低而开发。此外，GE团队将对喷气发动机叶片的3D打印仪表进行彻底的振动测试。 应变测量值的气溶胶射流的好处是喷气发动机仪器的巨大效果。与市售的应变传感器相比，将将3D打印的传感器小型化，从而提供一个平台，以最大程度地减少传感器对流动路径的负面影响，并且由于其相对较小的尺寸和厚度与市售传感器相比，它们的零件响应。 这项技术的结果将普遍存在，并将对许多行业（例如航空航天，汽车和能源）产生深远而广泛的影响，这些行业将受益于更多的按需微型3D打印的应变计。