Method of instrumenting a component

• US 20050287386A1
• Filed: 08/30/2005
• Published: 12/29/2005
• 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, Sabol, Stephen M.
• Granted Patent: US 7,572,524 B2
• Time in Patent Office: Days
• US Class Current: 428/543
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: F01D 17/02 Arrangement of sensing elements
• CPC Class Codes: F01D 17/08 responsive to condition of working-fluid, e.g. pressure
• CPC Class Codes: F01D 17/085 to temperature
• CPC Class Codes: F01D 21/003 Arrangements for testing or measuring for measuring vibrations G01H
• CPC Class Codes: F05D 2230/30 with deposition of material
• CPC Class Codes: F05D 2230/90 Coating; Surface treatment manufacture with deposition of material F05D2230/30
• CPC Class Codes: F05D 2260/80 Diagnostics
• CPC Class Codes: G01H 1/006 of the rotor of turbo machines
• CPC Class Codes: G01P 15/0915 of the shear mode type
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/8305 Miscellaneous [e.g., treated surfaces, etc.]

Abstract

A method of instrumenting a first component (210) for use in a combustion turbine engine (10) wherein the first component (210) has a surface contacted by a second component during operation of the combustion turbine engine (10). The method may include depositing an insulating layer (260) on the surface of the first component (210) and depositing a first conductive lead (232, 254) on the insulating layer (260). A piezoelectric material (230) may be deposited in electrical communication with the first conductive lead (232, 254) and a second conductive lead (236, 256) may be deposited in electrical communication with the piezoelectric material (230) and be insulated from the first conductive lead (232, 254) to form a sensor (50) for detecting pressure exerted on the surface of the first component (210) during operation of the combustion turbine engine (10).

Claims

1. A method of instrumenting a first component for use in a combustion turbine engine, the first component comprising a surface contacted by a second component during operation of the combustion turbine engine, the method comprising:

depositing an insulating layer on the surface of the first component;

depositing a first conductive lead on the insulating layer;

depositing a piezo-material in electrical communication with the first conductive lead; and

depositing a second conductive lead in electrical communication with the piezo-material and insulated from the first conductive lead to form a sensor for detecting pressure exerted on the surface of the first component during operation of the combustion turbine engine.

2. The method of claim 1, the steps of depositing comprising using a direct write thermal spray process.

3. The method of claim 1 further comprising forming the sensor in a worn surface of the component.

4. The method of claim 3 further comprising depositing a wear resistant coating over the sensor.

5. The method of claim 1 further comprising forming the sensor as a load cell.

6. The method of claim 1 further comprising depositing a central mass to form the sensor as an accelerometer.

7. The method of claim 1 further comprising:

forming at least one trench to a predetermined depth in a layer of barrier coating material deposited on the surface of the first component; and

forming the sensor within the at least one trench.

8. The method of claim 7 further comprising:

refilling the at least one trench with a protective coating.

9. A component comprising:

an insulating layer deposited on a surface of the component;

a first conductive lead deposited on the insulating layer;

a piezo-material deposited on the first conductive lead; and

a second conductive lead deposited on the piezo-material to form a sensor for detecting pressure exerted on the surface of the component.

10. The component of claim 9 further comprising a protective coating deposited over the sensor.

11. The component of claim 9 further comprising a central mass deposited within the piezo-material to form the sensor as an accelerometer.

12. The component of claim 9 further comprising:

a wear resistant coating deposited on the surface of the component; and

at least one trench formed in the wear resistant coating wherein the sensor is deposited within the at least one trench.

13. The component of claim 12 further comprising a wear resistant coating deposited over the sensor.

14. A component for use in a combustion turbine engine, the component comprising a piezo-material embedded beneath a surface of the component, the surface being contacted by a second component during operation of the combustion turbine engine.

15. The component of claim 14 further comprising a wear resistant material defining the surface of the component.

16. The component of claim 14 further comprising a central mass deposited within the piezo-material forming an accelerometer.

17. The component of claim 14 further comprising:

a first conductive lead extending from the piezo-material to a termination location; and

a second conductive lead extending from the piezo-material to the termination location.

18. The component of claim 14 further comprising:

a barrier coating material defining the surface of the component; and

at least one trench formed within the barrier coating material wherein the piezo-material is deposited within the at least one trench.

19. The component of claim 18 further comprising:

a first conductive lead deposited within the at least one trench and extending from the piezo-material to a termination location; and

a second conductive lead deposited within the at least one trench and extending from the piezo-material to the termination location whereby a load cell is formed for detecting a load on the surface of the component during operation of the combustion turbine engine.

20. A method of instrumenting a component for use in a combustion turbine engine, the component comprising a conductive substrate, the method comprising:

depositing a piezo-material on a surface of the conductive substrate;

depositing an insulating layer on the conductive substrate to a termination location; and

depositing a conductive lead on the insulating layer extending from the piezo-material to the termination location.

21. The method of claim 20 wherein the surface is contacted by a second component during operation of the combustion turbine engine.

22. The method of claim 20 further comprising:

forming a recess within the surface of the conductive substrate; and

depositing the piezo-material in the recess.

23. The method of claim 22 further comprising depositing a wear resistant coating over the piezo-material.

24. The method of claim 20 wherein the surface is non-planar and the steps of depositing comprising using a direct write thermal spray process.