“Maintenance jets is very expensive and time consuming, especially for blade fatigue monitoring, but if the humans are wearing mobile health equipment to monitor their blade operations in real time? This is possible with 3D printed sensors. The installation of sensors on aerospace components can help optimize the process of maintaining a jet."
Optomec Aerosol Jet Technology
Optomec Aerosol Jet technology enables Swansea University researchers to directly print strain and optical creep sensors for use on the surface of compressor blades on jet engines. Using laser detection systems and optically-measured sensors, researchers were able to determine the creep of a component within 10 nanometers. The Welsh Printing and Coating Center Researcher (WCPC) believes that this allows the condition of the blade to be monitored and improves fuel efficiency and engine operating temperatures.
3D printing process (Wales Printing and Coating Center)
The process of printing the sensor begins with atomizing the nano-silver conductive ink with a mist generator, first by inducing the deposition head by flow aerodynamics, producing a sheath gas annular flow. The substrate is aligned by a nozzle and concentratedly injected at a coaxial flow rate. The pattern of the material is done by numerical control commands, while the distance between the deposition head and the substrate remains constant while the substrate remains fixed to ensure accurate deposition of the material.
3D printed creep sensor. (Wales Printing and Coating Center)
After the ink is deposited, it is heat treated to give the sensor the correct conductivity and mechanical properties. In addition, local processing is possible, using a laser processing process that allows the materials used to have very low temperature tolerances. The end result is a high-quality film that is as thin as a 10 nm edge definition for high performance.
Temperature limit
Although WCPC researchers are using nano-silver inks, the material is stable at 250 degrees Celsius, and they are also developing high-temperature components for nano-platinum inks (1200 degrees Celsius). If successful, it will be very meaningful, because the temperature limit of the sensor is a major problem in the aerospace industry.
3D Print Print Sensor (Welsh Printing and Coating Center)
These 3D printed sensors are currently available for low pressure turbine blades, but not for high pressure turbine blades. The high pressure turbine is located downstream of the burner so it is subjected to the highest temperature. Low-pressure turbines have less heat and fewer compressor blades, so 3D printed sensors can be used on these low-voltage components. Sensors monitor their pressure and the degree of creep. Of course, high-pressure turbine blades require such monitoring because their pressure and creep change.
REVIEW
With the development of the Internet of Things, all the common objects that can perform independent functions can be interconnected, and the real-world digitalization will be in the fields of transportation and logistics, health care, intelligent environment (home, office, factory), personal and Social areas and other interconnections. The technological development of sensors plays an important role in promoting the development of the Internet of Things.
Sensors will be widely used in areas such as automotive, consumer electronics, industrial automation, telecommunications, building automation, aerospace and defense, medical, and railway. In particular, there is a great demand in the field of consumer electronic devices, such as mobile phones, media players, smart TVs, home theater systems, digital cameras, washing machines, wearable devices, gaming devices and the like.
Optomec's technology will have a lot to offer in the sensor field due to its uniqueness. Currently, GE Ventures, a subsidiary of GE, and Autodesk Spark Investment Fund, a subsidiary of Autodesk, have invested in Optomec's technology.
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