Laser Sensor Deposition on Functional Layers
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Solution Overview
Problem
Existing methods for embedding high-temperature sensors in functional layers, such as those used in turbine blades, often damage the layers due to excessive heat input and require complex masking processes, limiting their efficiency and service life.
Innovation Solution
A method using laser build-up welding to apply sensor materials directly to the functional layer without masks, adjusting process parameters to minimize heat input and ensure the sensor structures are smaller than the layer thickness, allowing for real-time monitoring without significant thermomechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal spraying processes, sputtering, or arc deposition are used to embed sensors in functional layers, then sensors can be manufactured, but the microstructural properties of the functional layer are significantly changed and thermomechanical stresses are generated
Solution Approach 1:
The patent changes the fundamental process parameters from high-energy deposition methods (thermal spraying, sputtering, arc deposition) to laser melting with controlled heat input. By adjusting laser power, scanning speed, and beam focus, the process achieves sensor deposition while maintaining the functional layer's microstructural integrity and minimizing thermomechanical stresses.
2Manufacturing precision
If masks or collimator screens are used to create fine sensor structures, then sensor fineness is achieved, but application efficiency is severely limited and process complexity increases
Solution Approach 1:
The patent extracts and eliminates the masking step entirely from the process. Instead of applying masks to the substrate and then depositing material, the method directly deposits sensor material only where needed using a focused laser beam, achieving fine sensor structures without any masking or collimator screens, thereby dramatically improving application efficiency.
3Ease of manufacture
If high heat input is applied during sensor production, then sensor material can be deposited, but the functional layer or component is damaged above critical rates
Solution Approach 1:
The patent applies local quality by concentrating the laser energy in a highly focused beam that melts and deposits sensor material only at the specific deposition location. The heat input is localized to the immediate sensor deposition zone, while the surrounding functional layer remains unaffected, enabling easy manufacturing without damaging the component.
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 enables the production of dense, uninterrupted sensor structures that can operate at high temperatures (up to 1500°C) with minimal impact on the functional layer, providing real-time data and improved application efficiency compared to traditional methods.
Implementation Method 1
the material being at least partially melted in a laser beam and then applied to the surface
Implementation Method 2
a method similar to laser build-up welding without the use of masks
Implementation Method 3
as a ceramic sensor, can generate voltages itself (piezo effect)
Implementation Method 4
Metal thermistors or PTC thermistors, in which the internal resistance changes with the temperature
Data Source
Figure 1a~1b
Figure 2a~3
Figure 4
AI summary
The invention relates to a process for producing a sensor on the surface of a functional layer, in which suitable sensor material in the form of powder or a wire is melted in a laser beam with the aid of a process similar to laser build-up welding and is then applied to the surface of the functional layer. The invention provides a much improved process for producing sensors, in particular also in-situ sensors, wherein the sensors can also be deposited on a functional layer that is partially very coarse without the - previously customary - need for elaborate masks to be used. The easy adaptability of the process parameters provides a broad application area, both with respect to the sensor to be produced and with respect to the functional layer to be detected. The sensors produced in this way are used in particular for the detection of components exposed to high temperatures or the functional layers thereof. The sensors that can be produced according to the invention particularly include temperature sensors, pressure or stress sensors or else acceleration sensors.