Printing Embedded Sensors for Turbine Blades by Electro-spraying Polymer Derived Ceramics

该奖项为实现将低调陶瓷传感器直接打印到涡轮叶片等曲面上的新技术提供资金。在所提出的工艺中，将对液态聚合物前驱体墨水进行电喷雾、固化和热解，以产生表面一致的陶瓷传感器元件。为了适应印刷，需要特别考虑油墨的流变性和导电性。该研究计划结合电喷雾过程的实验和建模，考虑传感器功能、设备分辨率和耐用性。研究结果可能会在发电厂、核反应堆、煤矿和飞机等恶劣环境中需要表面一致性和低调的传感器应用中得到广泛应用。所提出的印刷方法具有快速、低成本的潜在制造优势。这里的重点将是涡轮叶片，如果成功完成，将能够对在越来越高的温度下运行的涡轮进行实时、现场的热和机械测量。获得的数据将增强发动机控制、健康监测和设计优化，并有助于提高运行期间的效率和可靠性。研究生将直接参与该项目，K-12年级的学生将受益于先进印刷工艺概念的课堂演示。

This award provides funding for the realization of a new technology for direct printing of low-profile ceramic sensors onto curved surfaces such as turbine blades. In the proposed process a liquid phase polymer precursor ink will be electrosprayed, cured, and pyrolyzed to yield a surface-conformed ceramic sensor element. To be amenable to printing, special consideration of the ink rheology and electrical conductivity is required. The research plan is a combination of experiments and modeling of the electrospray process with consideration of sensor functionality, device resolution and durability.The research results could find broad use where surface conformance and low profile are needed for sensor applications in harsh environments such as power plants, nuclear reactors, coal mines and aircraft. The proposed printing method has the potential manufacturing advantages of being rapid and low-cost. The focus here will be on turbine blades and successful completion would enable real time, in situ thermal and mechanical measurements in turbines which operate at increasingly higher temperatures. Acquired data would enable enhanced engine control, health monitoring, and design optimization as well as contribute to improved efficiency and reliability during operation. Graduate students will be directly involved in the project and K-12 students will benefit from classroom demonstration of advanced printing process concepts.