Embedded Sensor Multi-Layer Wall Structure for Gas Turbine Reliability
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Solution Overview
Problem
Existing gas turbine engines face challenges in effectively integrating sensors into their components to monitor health and conditions, such as wear, temperature, and pressure, due to limitations in sensor placement and durability within the harsh operational environment.
Innovation Solution
A multi-layer wall structure with embedded sensors, specifically optical fibers, pressure transducers, or strain gauges, is formed using metallic layers like nickel, steel, and titanium, bonded together using ultrasonic welding, providing a robust and durable solution for sensor integration, particularly at the leading edge of airfoil sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are placed adjacent to airfoil sections using sensor blankets or cavities, then sensor integration is achieved, but structural integrity and reliability are compromised
Solution Approach 1:
The sensor is metallurgically bonded directly to the airfoil section, merging the sensor with the structural component itself. This eliminates separate sensor mounting structures (blankets or cavities) and creates a unified structure where the sensor becomes an integral part of the airfoil, maintaining structural integrity while achieving reliable sensor integration
Solution Approach 2:
The invention uses a multi-layer metallic structure where different metal layers (e.g., nickel, steel, cobalt, titanium) are bonded together to form a composite structure. The sensor is embedded within this composite metallic structure, allowing the integration of sensing functionality while maintaining the mechanical strength and durability of the airfoil through the composite material system
2Reliability
If multiple metal layers are bonded together to embed sensors, then sensor mounting reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The airfoil structure is divided into multiple discrete metal layers that can be manufactured separately and then bonded together. This segmentation allows each layer to be optimized for specific functions (structural support, sensor embedding, corrosion resistance) while simplifying the manufacturing of individual components before assembly
Solution Approach 2:
The sensor is embedded within the multi-layer metallic structure during the manufacturing process itself, rather than being added as a separate post-processing step. The metal layers are bonded together with the sensor already in place, performing the sensor integration action preliminarily during formation of the structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures reliable sensor mounting and accurate data collection from engine components, enhancing monitoring capabilities and structural integrity by staggering seams between metallic layers for reduced delamination and increased structural integrity.
Implementation Method 1
The at least one layer of metallic material and the sensor are joined using an ultrasonic welding process
Data Source
Figure 1
Figure 2~3
Figure 4A~4E
AI summary
One exemplary embodiment of this disclosure relates to an article having a multi-layer wall structure having an embedded sensor. Further, the multi-layer wall structure and the sensor are bonded together.