High Temperature Sensor Materials Optimization and Fabrication Methods

The purpose of this project is to demonstrate the feasibility of using an innovative, nanoparticle inkjet process for directly writing high temperature health monitoring sensors on turbine engine and thermal protection system components without the need for expensive sputtering, CVD, clean room or photolithography equipment. The inkjet process allows sophisticated sensor geometries and material combinations to be produced on the component in a matter of minutes as opposed to the hours needed to produce the sensors using the conventional clean room/sputtering approach. The nanoparticle inkjet process is capable of applying a wide variety of ceramic and refractory metal materials. In this project a number of ceramic materials will be investigated for high temperature strain and TC sensor use. These materials are conductive ceramics that are stable at high temperatures in air and oxidizing environments up to or exceeding 1600° C. BENEFIT: The development of low cost, robust, high temperature sensors will allow: 1) the monitoring of critical structures for degradation during space vehicle reentry, 2) measuring the operating parameters in extremely hot environments such as the compressor and turbine sections to validate computer modeling codes, 3) allow active control of pressure surges in turbine engines, 4) allow the ability to diagnose turbine engine and thermal protection system health and estimate component capability for future missions, 5) and help reduce the significant costs of testing and qualifying turbine engines.