Grant: Alliance Grants
University of Waterloo
$153,846.00
Micro-scale Additive Manufacturing (3D Printing) of High-Temperature Strain Sensors on Non-Planar Surfaces of Jet Engine Components
EF 2023-24
Résumé
This project aims to strengthen a collaborative project between the University of Waterloo (UW) and GE Aviation, in which micro-scale additive manufacturing (AM), known as 3D printing, is deployed to fabricate high-temperature strain gauges on the non-planar surface of jet engine components. Given the opportunities provided by micro-scale aerosol-jet AM and the importance of health monitoring, load detection, and effective strain and vibration measurements in critical aerospace parts, this new phase of the project is proposed to capitalize on the patented technology developed through the previous partnership between GE Aviation and UW to eventually push the technology to a higher Technology Readiness Level of 6. To this end, several objectives are proposed to develop comprehensive recipes for enabling 3D printing of defect-free long tracks via aerosol jet printing of Palladium-Chromium (Pd-Cr) and Alumina inks to meet jet engine requirements. In addition, a Pd-Cr ink with a low-temperature sintering property will be developed to minimize the side effect of high temperature on components. This will be supported by an advanced lead attachment procedure that will be developed based on the reduction of sintering temperature and numerical simulation. In addition, thorough vibration tests on 3D printed gauges on jet engine blades will be conducted in harsh and high-temperature environments by the GE team. The benefit of aerosol-jet AM of strain gauges for jet engine instrumentation is tremendous. The 3D printed sensors will be miniaturized compared to commercially available strain sensors thus offering a platform to minimize a negative impact of sensors on the flow path and part response due to their relatively small size and thickness compared to commercially available sensors. The outcome of this technology will be pervasive and will have a deep and broad impact on many industries (e.g., aerospace, automotive and energy) that will benefit from more on-demand miniaturized 3D printed strain gauges.
Programme
Alliance Grants
Bénéficiaire
Emplacement
Ontario, Canada
Type de bénéficiaire
Academia
Type
Grant
Source
NSERC's Awards Data
Tel que publié
Application id
576693-2022
Name nom
Toyserkani, Ehsan E
Department département
Mechanical Engineering and Mechatronics
Organization id
33
Institution établissement
University of Waterloo
Province en
Ontario
Province fr
Ontario
Country en
CANADA
Country fr
CANADA
Fiscal year exercice financier
2023
Competition year année de concours
2022
Award amount
153846
Program id
ALLRP
Program name en
Alliance Grants
Program name fr
Subventions Alliance
Group en
RESEARCH PARTNERSHIPS
Group fr
PARTENARIATS DE RECHERCHE
Committee code
96
Committee name en
RPP Internal Decision Cttee
Committee name fr
Cté de décision interne - PPR
Area of application code
500
Area of application group en
Manufacturing processes and products
Area of application group fr
Procédés et produits industriels
Area of application en
Manufacturing processes and products
Area of application fr
Procédés et produits industriels
Research subject code
2109
Research subject group en
Mechanical engineering
Research subject group fr
Mechanical systems and instrumentation
Research subject en
Génie mécanique
Research subject fr
Instrumentation et systèmes mécaniques
Application title
Micro-scale Additive Manufacturing (3D Printing) of High-Temperature Strain Sensors on Non-Planar Surfaces of Jet Engine Components
Keyword
3D Printing; Additive Manufacturing; Direct-Write Printing; Micro-Scale Aerosol Jet 3D Printing; Non-planar Surfaces; Strain Sensors
Application summary
This project aims to strengthen a collaborative project between the University of Waterloo (UW) and GE Aviation, in which micro-scale additive manufacturing (AM), known as 3D printing, is deployed to fabricate high-temperature strain gauges on the non-planar surface of jet engine components. Given the opportunities provided by micro-scale aerosol-jet AM and the importance of health monitoring, load detection, and effective strain and vibration measurements in critical aerospace parts, this new phase of the project is proposed to capitalize on the patented technology developed through the previous partnership between GE Aviation and UW to eventually push the technology to a higher Technology Readiness Level of 6. To this end, several objectives are proposed to develop comprehensive recipes for enabling 3D printing of defect-free long tracks via aerosol jet printing of Palladium-Chromium (Pd-Cr) and Alumina inks to meet jet engine requirements. In addition, a Pd-Cr ink with a low-temperature sintering property will be developed to minimize the side effect of high temperature on components. This will be supported by an advanced lead attachment procedure that will be developed based on the reduction of sintering temperature and numerical simulation. In addition, thorough vibration tests on 3D printed gauges on jet engine blades will be conducted in harsh and high-temperature environments by the GE team. The benefit of aerosol-jet AM of strain gauges for jet engine instrumentation is tremendous. The 3D printed sensors will be miniaturized compared to commercially available strain sensors thus offering a platform to minimize a negative impact of sensors on the flow path and part response due to their relatively small size and thickness compared to commercially available sensors. The outcome of this technology will be pervasive and will have a deep and broad impact on many industries (e.g., aerospace, automotive and energy) that will benefit from more on-demand miniaturized 3D printed strain gauges.
