Thermal Barrier Coated Component Sensor Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In thermal barrier coated components, sensors disposed between the top coat layer and the bond coat layer face challenges due to heat elongation differences, leading to potential delamination and inadequate long-term monitoring or evaluation in high-temperature environments.
Innovation Solution
A configuration involving a base material with a first bond coat layer, a sensor unit, a second bond coat layer with higher surface roughness to cover the sensor unit, and a top coat layer, where the second bond coat layer has increased porosity and is thinner than the first bond coat layer, improving adhesion and preventing delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is disposed on the interface between the top coat layer and the bond coat layer, then thermal boundary conditions can be detected for soundness monitoring, but the sensor cannot withstand long-term use in high-temperature environment due to heat elongation difference and top coat layer delamination
Solution Approach 1:
A second bond coat layer is introduced as an intermediary layer between the sensor unit and the top coat layer. This intermediate layer absorbs the heat elongation difference through its porous structure and higher surface roughness, preventing direct thermal stress transmission to the sensor and top coat interface, thereby enabling long-term reliable operation in high-temperature environments while maintaining detection capability
2Strength
If the second bond coat layer with higher surface roughness is formed to cover the sensor unit, then the degree of adhesion between the bond coat layer and top coat layer is improved, but the device structure becomes more complex
Solution Approach 1:
The bond coat layer is segmented into two distinct layers: a first bond coat layer providing the base bonding function, and a second bond coat layer with higher surface roughness and porosity specifically designed to cover the sensor unit and enhance adhesion to the top coat layer. This segmentation allows each layer to perform its specialized function optimally while maintaining overall structural integrity
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 configuration enables long-term monitoring and evaluation of thermal barrier coated components by preventing delamination and ensuring the sensor can accurately detect thermal boundary conditions in high-temperature environments.
Implementation Method 1
a second bond coat layer that is formed on the first bond coat layer so as to cover at least the sensor unit and has a surface roughness higher than that of the first bond coat layer
Implementation Method 2
the degree of adhesion between the second bond coat layer and the top coat layer can be improved
Implementation Method 3
the second bond coat layer includes more pores than the first bond coat layer
Implementation Method 4
there is a heat elongation difference (difference in coefficient of thermal expansion) between the top coat, and the sensor
Data Source
AI summary
The present invention provides a thermal barrier coated component, monitoring or evaluation of the soundness of which is able to be adequately carried out on the basis of the thermal boundary conditions that are detected by a sensor. A thermal barrier coated component according to the present invention comprises: a base material; a first bond coat layer that is a metal bonding layer formed on the base material; a sensor unit that comprises a sensor and a conductive wire, which are formed on the first bond coat layer; a second bond coat layer that is formed on the first bond coat layer so as to cover at least the sensor unit, while having a surface roughness higher than that of the first bond coat layer; and a top coat layer that is formed on the second bond coat layer.