Method and apparatus for instrumenting a gas turbine component having a barrier coating

• US 6,838,157 B2
• Filed: 09/23/2002
• Issued: 01/04/2005
• Est. Priority Date: 09/23/2002
• Status: Active Grant

• Current Assignee: Siemens Energy Incorporated (Siemens AG)
• Original Assignee: Siemens Westinghouse Power Corporation
• Inventors: Subramanian, Ramesh
• Primary Examiner(s): MCNEIL, JENNIFER C
• Application Number:
  US10/252,236
• Publication Number:
  US 20040202886A1
• Time in Patent Office: 834 Days
• Field of Search: 427/446, 427/455, 427/554, 427/556, 428/193, 428/320.2, 428/332, 428/632, 428/633, 428/596
• US Class Current: 428/173
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: C23C 24/04 Impact or kinetic deposition of particles
• CPC Class Codes: C23C 28/00 Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
• CPC Class Codes: C23C 4/18 After-treatment
• CPC Class Codes: F23M 11/00 Safety arrangements
• CPC Class Codes: F23M 5/00 Casings; Linings; Walls
• CPC Class Codes: F23R 3/007 constructed mainly of ceramic components
• CPC Class Codes: G01N 3/56 Investigating resistance to wear or abrasion
• CPC Class Codes: Y10T 428/12361 having aperture or cut
• CPC Class Codes: Y10T 428/12611 Oxide-containing component
• CPC Class Codes: Y10T 428/2462 with partial filling of valleys on outer surface
• CPC Class Codes: Y10T 428/249994 Composite having a component wherein a constituent is liquid or is contained within preformed walls [e.g., impregnant-filled, previously void containing component, etc.]
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension

Abstract

A method (50) of instrumenting a component (10) having a barrier coating (14). A sensor (76) is embedded within or below the coating. Material forming the sensor is deposited within a trench (80) formed into the barrier coating. The trench is then backfilled with material (70) to protect the sensor from the environment within which the component is operating. In this manner, the sensor may be embedded at any desired location and any desired depth within a barrier coating on a previously fabricated component. An array of sensors (98, 100, 102) may be embedded across the depth of the coating to provide signals indicative of operating conditions across the coating. The signals may be conducted to a connection location (24) by conductors (62, 64) that are deposited within the trench. The trench may be formed with a laser engraving process (54) and the material for the sensor and conductors may be deposited with a selective laser melting process (58).

Claims

1. A method for instrumenting a component having a barrier coating, the method comprising:

forming a trench to a predetermined depth in a layer of a barrier coating material deposited on a surface of a component;

depositing a material comprising a sensor into the trench, and

depositing a layer of a barrier material into the trench over the sensor.

2. The method of claim 1, further comprising:

depositing a first material into a first portion of the trench; and

depositing a second material into a second portion of the trench, the second material making electrical contact with the first material.

3. The method of claim 1, further comprising:

forming the trench to extend from a sensing location to a connection location on the component; and

depositing at least one layer of material into the trench at the sensing location to form a sensor; and

depositing a layer of a conducing material into the trench to form a conductor from the sensing location to the connection location for conducting a signal generated by the sensor to the connection location.

4. The method of claim 3, further comprising forming the trench to a predetermined width to affect a performance parameter of the conductor.

5. The method of claim 1, further comprising:

depositing a first layer of conducting material into the trench;

depositing a layer of an insulating material into the trench to form an insulator over the first layer of conducting material; and

depositing a second layer of conducting material into the trench over the insulator.

6. The method of claim 1, further comprising forming the trench to a predetermined width to affect a performance parameter of the sensor.

7. The method of claim 1, further comprising forming the trench by laser engraving.

8. A method for instrumenting a component having a barrier coating, the method comprising:

forming a trench to a predetermined depth in a layer of a barrier coating material deposited on a surface of a component;

depositing a material comprising a sensor into the trench;

forming the trench to extend from a sensing location to a connection location on the component; and

depositing at least one layer of material into the trench at the sensing location to form a sensor;

depositing a layer of a conducting material into the trench to form a conductor from the sensing location to the connection location for conducting a signal generated by the sensor to the connection location; and

refilling the trench with a layer of a barrier material.

9. A method for instrumenting a component having a barrier coating, the method comprising:

forming a trench to a predetermined depth in a layer of a barrier coating material deposited on a surface of a component;

depositing a material comprising a sensor into the trench;

depositing material into the trench in the form of a powder; and

melting the powder in the trench with a beam of laser energy.

10. A method for instrumenting a component having a barrier coating, the method comprising:

forming a trench to a predetermined depth in a layer of a barrier coating material deposited on a surface of a component;

depositing a material comprising a sensor into the trench

forming the trench to a predetermined depth in the layer of barrier coating material to position the sensor at a desired depth;

forming a first trench at a first depth in the layer of barrier coating material;

depositing material into the first trench to form a first sensor;

forming a second trench at a second depth in the layer of barrier coating material; and

depositing material into the second trench to form a second sensor.

11. A method for instrumenting a component having a barrier coating, the method comprising:

forming a trench to a predetermined depth in a layer of a barrier coating material deposited on a surface of a component;

depositing a material comprising a sensor into the trench;

depositing a first layer of thermal barrier coating material onto a surface of the component;

forming a first trench in the first layer of thermal barrier coating material;

depositing material into the first trench to form a first sensor;

depositing a second layer of thermal barrier coating material onto the first layer of barrier coating material;

forming a second trench in the second layer of thermal barrier coating material; and

depositing material into the second trench to form a second sensor.

12. The method of claim 11, wherein the second trench is disposed above the first trench along a line perpendicular to the surface.

13. A method of instrumenting a gas turbine engine, the gas turbine engine including a component having a barrier coating formed thereon, the method comprising:

selecting a sensing location on a component of a gas turbine engine;

forming a trench in a barrier coating deposited on the component at the sensing location;

depositing material into the trench to form a sensor at the sensing location; and

backfilling the trench over the sensor with an insulating material.

14. The method of claim 13, further comprising forming the trench with a laser engraving process.

15. A method of instrumenting a gas turbine engine, the gas turbine engine including a component having a barrier coating formed thereon, the method comprising:

selecting a sensing location on a component of a gas turbine engine;

forming a trench in a barrier coating deposited on the component at the sensing location;

depositing material into the trench to form a sensor at the sensing location;

backfilling the trench over the sensor with an insulating material; and

depositing the insulating material into the trench with a selective laser melting process.

16. A method of instrumenting a gas turbine engine, the gas turbine engine including a component having a barrier coating formed thereon, the method comprising:

selecting a sensing location on a component of a gas turbine engine;

forming a trench in a barrier coating deposited on the component at the sensing location;

depositing material into the trench to form a sensor at the sensing location;

backfilling the trench over the sensor with an insulating material; and

backfilling the trench with a ceramic thermal barrier coating material using a selective laser sintering process.

17. A component for use in a gas turbine engine comprising:

a substrate;

a barrier coating deposited on a surface of the substrate;

a trench formed in the barrier coating;

a sensor formed in the trench; and

a backfill material deposited in the trench over the sensor.

18. The component of claim 17, further comprising:

the trench extending from a sensing location to a connection location;

a conductor connected to the sensor and extending within the trench from the sensing location to the connection location; and

the backfill material deposited over the sensor and over the conductor.

19. The component of claim 17, further comprising:

a plurality of trenches formed in the thermal barrier coating at respective different depths below a surface of the thermal barrier coating;

a sensor formed in each trench; and

a backfill material deposited in each trench over the respective sensor.

20. A component for use in a gas turbine engine comprising:

a substrate;

a barrier coating deposited on a surface of the substrate;

a trench formed in the barrier coating;

a sensor formed in the trench;

a backfill material deposited in the trench over the sensor; and

a bond coat deposited between the substrate and the thermal barrier coating

the trench extending through the barrier coating to a depth proximate an interface between the bond coat and the barrier coating; and

the sensor formed proximate the interface between the bond coat and the barrier coating.

21. A method of instrumenting a component of a gas turbine engine, the method comprising:

depositing a sensor onto a surface of a component of a gas turbine engine;

depositing a barrier coating over the sensor;

depositing a second sensor over the barrier coating; and

depositing a second barrier coating over the second sensor.