Sensor Integration on Additively Manufactured Hot Section Components for Wireless Gas Turbine Prognostics

To realize the full capability of additively manufactured components in complex energy systems, it is imperative to minimize early component failures during development phases and during operation. Traditional field feedback timelines and offline inspection protocols are insufficient to meet faster-to-market product deployment requirements. Introducing additive manufacturing (AM) approaches can dramatically accelerate development timelines and offers the ability to measure critical parameters in locations that may have been infeasible before given sensor integration requirements. In turn, these measurements can facilitate condition-based operations and maintenance (CBOM) approaches that ultimately lead to reduced operational costs. To fulfill these goals, the current study is developing a method by which to reliably integrate sensors into additively manufactured gas turbine components with applications for both power generation and propulsion. Wireless measurement capabilities are also included as part of the demonstration process through using AM waveguides integral to the tested hardware. A phased demonstration approach is implemented to evaluate sensors deposited on AM parts beginning with simple coupons and increasing in complexity to turbine airfoils and combustor liner hardware. Throughout this approach, considerations of AM surface roughness, sensor performance and durability, and integrated wireless sensing are at the forefront for assessment.