Method and apparatus for instrumenting a gas turbine component having a barrier coating
View Patent ↗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 ).
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.