Method of instrumenting a component
View Patent ↗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 ).
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.