SBIR Phase I: High Pressure, High Temperature Thin Film Sensors

这个小型企业创新研究(SBIR)第一阶段项目将演示高温、高压传感器的制造，用于测量移动表面之间的接触应力。摩擦和高接触应力造成的磨损是设计和分析机械部件(如齿轮和轴承)的主要因素。由于表面之间真实接触区域的不确定性，除了使用模型来预测这些接触应力之外，别无选择。许多分析模型被用来预测在不同位置发生的表面应力。然而，由于缺乏准确的实验数据，这些模型的实际验证是困难的，因为没有能够承受高达900oK的温度和许多GPa数量级的压力的传感器。此外，这些传感器必须能够在不干扰接触运动的情况下进行点接触。虽然市场上有许多类型的传感器，但这些传感器都不能现场测量所需的参数。第一阶段将开发一种新型的非侵入性传感器，能够承受这些温度和压力的极端情况，同时提供准确的实时数据。第二阶段将集中于这种传感器的结构-性能-性能的优化和可用于各种应用的生产原型的制造。应力和应变传感器有多种商业应用。其中一些包括用于汽车和工业齿轮、监测切割和机床的切削力、用于飞机发动机和发电机涡轮机的智能传感器、用于现场监测延长汽车发动机和相关部件寿命的润滑需求的智能传感器以及用于研究实验室的分析仪器。

This Small Business Innovative Research (SBIR) Phase I project will demonstrate the fabrication of a high temperature, high pressure sensor for measuring contact stresses between moving surfaces. Wear due to friction and high contact stresses is a major factor in the design and analysis of mechanical components such as gears and bearings. Due to the uncertain nature of the real area of contact between surfaces, there is no recourse but to use models to predict these contact stresses. Numerous analytical models are used to predict surface stresses occurring at various locations. However, actual verification of these models is difficult due to a lack of accurate experimental data since there are no sensors capable of withstanding temperatures as high as 900oK and pressures on the order of many GPa. Furthermore, these sensors must be capable of making a point contact without interfering with the contact motions. Although many types of sensors are available on the market, none of these can measure the required parameters in situ. Phase I will develop a novel non-invasive sensor capable of withstanding these temperature and pressure extremes while delivering accurate real-time data. Phase II would concentrate on the optimization of structure-property-performance of this sensor and fabrication of a production prototype that can be used in a wide variety of applications. Stress and strain sensors have a multitude of commercial applications. Some of them include use in automobile and industrial gears, monitoring cutting forces in cutting and machine tools, smart sensors for aircraft engines and power generator turbines, smart sensors for in-situ monitoring of lubrication needs to extend life of automotive engines and associated components, and in analytical instrumentation in research laboratories.