Direct Write Thermal Spraying of Mesoscale Electronics and Sensor Structures. Novel Approaches to Integrating Sensors on Structures

Transcription

1 Direct Write Thermal Spraying of Mesoscale Electronics and Sensor Structures Novel Approaches to Integrating Sensors on Structures S.Sampath, R.Gambino, J.Longtin and H.Herman Center for Thermal Spray Research Department of Materials Science and Engineering State University of New York Stony Brook, NY R.Greenlaw Integrated Coating Solutions Huntington Beach, CA

2 Thermal Spray Direct Write Technology Virtues and Unique Advantages High through-put manufacturing High speed direct writing capability In situ rapid application of metals, ceramics and polymers W/o thermal treatment or post processing (Once we write we are done!!) In situ incorporation of multilayers & functionally graded layers Useful functional material properties in as-deposited state Cost effective and efficient Process virtually in any environment Minimal heat input into the substrate Al 2 O 3 Ni Graded

3 Thermal Spray Direct Write Deposition Capabilities Range of Geometries Blanket Deposits: Films and Coatings Patches Lines Vias Thick deposits and 3-D structures On plastic, metals, textile and ceramic substrates Conformal structures On pre-existing components and structures Ability to overcoat with a variety of materials for harsh environment applications Extrordinary Materials Versatility Dielectrics and sensor ceramics alumina, zirconia, yttria, BaTiO3, BST Conductors Cu and Ag Sensor materials NiCr, NiAl, Mo, NiCu etc. Magnetics Permalloy) and MnZn ferrites Polymers Range of thermoplastics Semicondutors Si and Ge Antenna on Concrete With Polymer overcoat Alumina 50? m Permalloy

4 Mesoscale Direct Write Capability Height ~ 60? m Base Diameter ~ 350? m Height ~ 60? m Base Diameter ~ 350? m

5 Direct-Write Sensors for Harsh Environments Harsh Environments high temperatures,corrosive high vibration, wear, strain, thermal/load cycling, etc. => Intrinsic capability due to nature of thermal sprayed material and its application E-type thermocouple By direct write - chromel/constantan - up to 900+ C - high sensitivity (> 45 mv/ C) - High reproducibility NiCu NiCr Alumina Voltage (mv) K-type thermocouple Seebeck coefficient S = 41.7?V / C 0 coating Temperature ( C) K-type thermocouple By direct write - chromel/alumel - up to C - good sensitivity - robust performance

6 Flame Impingement Test for Exposed and Embedded Direct Write Thermocouples MAPP flame on front of the embedded thermocouple, coated with YSZ thermal barrier coating Surface TC: 700 o C Embedded TC: 435 o C YSZ TBC thermocouple substrate in 9in 7in Thermocouple K-type S ~ 43? V/deg Temperature ( o C) Voltage (mv) bare coated (6 mils) Time (minutes) Response as a function of standoff distance Temperature ( o C)

7 Embedded Strain Gauge and Other Devices MICE strain gauges Commercial strain gauge Good repeatability Good linearity Negligible hysterisis Resistance change,? R/R (x10-6 ) Commercial SG, GF=2.085 Laser-cut SG-load, GF=1.328 Laser-cut SG-unload, GF= Strain,? (x10-6 ) 13 mm 3 mm 3 mm 15 mm Secondary Primary = Ni =Si Inductors/ Transformers Thermistors Magnetic Sensors RF Elements Microheaters

8 Applications in a wide range of industries Thermal Spray MICE allows sensor integration onto variety of structures embedded within structural coatings Infrastructure Aerospace Automotive Paper, Textile & Printing Industry Dental Implants/Prosthetics Mesoscale Electronics and Sensors

9 Conformal Direct Write Capability (Prototype Tool and System) Possible Direct-written multisensor configuration on a turbine blade Direct write antenna On helmet Conformal direct Write cell

10 Stony Brook Prototype Direct Write Tool Power Supply Deposition Powder Feed Integration and Control Feedstock Delivery Water Cooling Gas Powder Feed Motion Diagnostics Vision Fine Feature Development

11 Direct Write Sensors Mobile Application Possibilities *Support equipment, tethered lines, and effects of gravity omitted for simplicity