Sensors and Methods for Manufacturing Sensors

Simple SummaryContent extracted from patent full text and abstract with AI.

This invention relates to a method for producing sensors, especially in-situ sensors, directly onto or within functional layers (such as thermal barrier coatings) on machine parts using a laser-based process similar to laser cladding or laser additive welding. In this process, sensor material in powder or wire form is melted by a laser, deposited onto the layer, and forms a fine, dense sensor structure, such as temperature, pressure, strain, or acceleration sensors, without the need for complex masks or stencils. The technique is adaptable to various sensor and coating types and can be applied on even rough surfaces, improving manufacturing flexibility and efficiency.

Use CasesContent extracted from patent full text and abstract with AI.

• Real-time temperature monitoring of turbine blades or other components exposed to high temperatures.
• In-situ measurement of pressure or strain within protective coatings in jet engines or power plant turbines.
• Production of embedded sensors in thermal barrier or corrosion-resistant coatings on machine components.
• Integration of acceleration sensors within protective layers for machinery health monitoring.
• Quality control and degradation assessment in high-performance electronic devices or battery substrates.
• Development of 'intelligent coatings' that monitor their own performance or environmental conditions.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables direct deposition of sensor structures onto complex or rough surfaces without the need for elaborate masking, reducing process complexity and cost.
• Allows production of miniaturized and embedded sensors that minimally affect the properties of the underlying functional layer.
• Facilitates real-time (in-situ) monitoring of crucial parameters such as temperature, pressure, or strain, enabling rapid detection of problems and immediate operational adjustments.
• Improved quality and durability of sensor coatings due to dense, porosity-free deposition achieved by laser melting.
• Broad applicability due to adaptability of process parameters for various sensor and functional layer materials.
• Enhances maintenance and safety by providing continuous monitoring capabilities for critical, high-temperature, or high-stress components.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to a process for producing a sensor on the surface of a functional layer, in which suitable sensor material in the form of powder or a wire is melted in a laser beam with the aid of a process similar to laser build-up welding and is then applied to the surface of the functional layer. The invention provides a much improved process for producing sensors, in particular also in-situ sensors, wherein the sensors can also be deposited on a functional layer that is partially very coarse without the - previously customary - need for elaborate masks to be used. The easy adaptability of the process parameters provides a broad application area, both with respect to the sensor to be produced and with respect to the functional layer to be detected. The sensors produced in this way are used in particular for the detection of components exposed to high temperatures or the functional layers thereof. The sensors that can be produced according to the invention particularly include temperature sensors, pressure or stress sensors or else acceleration sensors.