Methods for producing strain sensors on turbine components

• US 9,546,928 B2
• Filed: 05/30/2014
• Issued: 01/17/2017
• Est. Priority Date: 05/30/2014
• Status: Active Grant

• Current Assignee: GE Infrastructure Technology, LLC (General Electric Company)
• Original Assignee: General Electric Company
• Inventors: Ward, John David Jr., Germann, Bryan Joseph, Burnside, Jason Lee, Hovis, Gregory Lee
• Primary Examiner(s): Kirkland, III, Freddie
• Application Number:
  US14/291,922
• Publication Number:
  US 20150346057A1
• Time in Patent Office: 963 Days
• Field of Search: 731/120.1
• US Class Current: 1/1
• CPC Class Codes: C23C 24/00 Coating starting from inorganic powder spraying of the coating material in molten state C23C4/00; solid state diffusion C23C8/00 - C23C12/00
• CPC Class Codes: C23C 30/005 on hard metal substrates
• CPC Class Codes: C23C 4/11 Oxides
• CPC Class Codes: F01D 17/04 responsive to load
• CPC Class Codes: F05D 2230/31 Layer deposition
• CPC Class Codes: F05D 2260/80 Diagnostics
• CPC Class Codes: F05D 2260/83 Testing, e.g. methods, components or tools therefor
• CPC Class Codes: F05D 2270/808 Strain gauges; Load cells
• CPC Class Codes: G01B 21/32 for measuring the deformation in a solid
• CPC Class Codes: G01L 1/2287 constructional details of the strain gauges adjustable resistors H01C10/00
• CPC Class Codes: G01M 15/14 Testing gas-turbine engines or jet-propulsion engines
• CPC Class Codes: G01M 5/0016 of aircraft wings or blades
• CPC Class Codes: G01M 5/0041 by determining deflection or stress

Abstract

Methods for manufacturing strain sensors on turbine components include providing a turbine component comprising an exterior surface, and, depositing a ceramic material onto a portion of the exterior surface to form a strain sensor comprising at least two reference points.

Claims

1. A method for manufacturing a strain sensor on a turbine component, the method comprising:

providing a turbine component comprising an exterior surface; and

,

depositing a ceramic material onto a portion of the exterior surface to form a strain sensor comprising at least two reference points, wherein the at least two reference points are at least partially separated by an exposed portion of the exterior surface, and further comprising depositing a visually contrasting material in the exposed portion.

2. The method of claim 1, wherein the turbine component comprises a nickel or cobalt based superalloy.

3. The method of claim 1, wherein the ceramic material comprises yttria-stabilized zirconia.

4. The method of claim 1, wherein the ceramic material is deposited using an aerosol jet coater.

5. The method of claim 1, wherein the ceramic material is deposited into a near net shape of the strain sensor.

6. The method of claim 1, wherein depositing the ceramic material further comprises forming a unique identifier.

7. The method of claim 1, wherein depositing the visually contrasting material in the exposed portion comprises uniformly depositing the visually contrasting material on an exterior surface of the turbine component prior to depositing the ceramic material.

8. The method of claim 1, wherein depositing a ceramic material onto a portion of the exterior surface to form the strain sensor comprising the at least two reference points further comprises defining a negative space between portions of the ceramic material, and the method further comprising depositing the visually contrasting material in the negative space whereby the ceramic material and the visually contrasting material form one substantial layer.

9. A method comprising:

providing a turbine component comprising an exterior surface;

depositing a ceramic material onto a portion of the exterior surface to form a strain sensor comprising at least two reference points, wherein the at least two reference points are at least partially separated by an exposed portion of the exterior surface,

depositing a visually contrasting material in the exposed portion;

monitoring the turbine component, the monitoring comprising;

measuring a second distance between a first of the at least two reference points of the strain sensor and a second of the at least two reference points of the strain sensor at a second time internal; and

,

comparing the second distance to a first distance between the first of the at least two reference points of the strain sensor and the second of the at least two reference points of the strain sensor from a first time interval.

10. The method of claim 9, wherein the at least two reference points are at least partially separated by an exposed portion of the exterior surface.

11. The method of claim 10, further comprising depositing a visually contrasting material in the exposed portion prior to measuring the second distance.

12. The method of claim 9, further comprising utilizing the turbine component in a turbine between the first and second time intervals.

13. The method of claim 9, wherein the turbine component comprises a nickel or cobalt based superalloy.

14. The method of claim 9, wherein the ceramic material comprises yttria-stabilized zirconia.

15. The method of claim 9, wherein depositing the visually contrasting material in the exposed portion comprises uniformly depositing the visually contrasting material on an exterior surface of the turbine component prior to depositing the ceramic material.

16. The method of claim 9, wherein depositing the ceramic material onto a portion of the exterior surface to form the strain sensor comprising the at least two reference points further comprises defining a negative space between portions of the ceramic material, and the method further comprising depositing the visually contrasting material in the negative space whereby the ceramic material and the visually contrasting material form one substantial layer.

17. A turbine component comprising:

an exterior surface; and

a strain sensor deposited on a portion of the exterior surface, the strain sensor comprising ceramic material and at least two reference points, and wherein the at least two reference points are at least partially separated by visually contrasting material, wherein the two reference points are at least partially separated by an exposed portion of the exterior surface and the visually contrasting material is in the exposed portion of the exterior surface of the turbine component prior to the ceramic material is deposited on the of the exterior surface.

18. A turbine component comprising:

an exterior surface; and

a strain sensor deposited on a portion of the exterior surface, the strain sensor comprising ceramic material and at least two reference points, and wherein the at least two reference points are at least partially separated by visually contrasting material, wherein the two reference points are at least partially separated by an exposed portion of the exterior surface to define a negative space between the two reference points of the ceramic material, and the visually contrasting material is in the negative space whereby the ceramic material and the visually contrasting material form one substantial layer.