Component with embedded sensor

Patent metadata

Field	Value
Publication number	US-2016305271-A1
Application number	US-201415036989-A
Country	US
Kind code	A1
Filing date	Nov 14, 2014
Priority date	Nov 15, 2013
Publication date	Oct 20, 2016
Grant date	—

Abstract

One exemplary embodiment of this disclosure relates to an article having a multi-layer wall structure having an embedded sensor. Further, the multi-layer wall structure and the sensor are bonded together.

First claim

What is claimed is:

1 . An article, comprising:
a multi-layer wall structure including an embedded sensor, the multi-layer wall structure and the sensor bonded together.

2 . The article as recited in claim 1 , wherein the multi-layer wall structure includes a plurality of metallic layers, the sensor bonded to at least two of the metallic layers.

3 . The article as recited in claim 2 , wherein each of the metallic layers includes more than one piece of material, wherein adjacent pieces of material establish a seam where the pieces of material abut one another, and wherein the metallic layers are arranged such that the seams are staggered relative to the seams of adjacent layers.

4 . The article as recited in claim 2 , wherein the metallic layers include at least one of nickel (Ni), steel, cobalt (Co), and titanium (Ti).

5 . The article as recited in claim 4 , wherein at least one of the metallic layers has a different chemical composition from at least one other metallic layer.

6 . The article as recited in claim 1 , wherein the sensor includes an optical fiber.

7 . The article as recited in claim 1 , wherein the multi-layer wall structure includes a plurality of sensors.

8 . The article as recited in claim 7 , wherein the plurality of sensors are selected from the group consisting of optical fibers, pressure transducers, temperature sensors, thermocouples, position sensors, and strain gauges.

9 . The article as recited in claim 1 , wherein the sensor is metallurgically bonded to the multi-layer wall structure during forming of the multi-layer wall structure.

10 . The article as recited in claim 1 , wherein the multi-layer wall structure includes a substantially arcuate shape, and wherein the multi-layer wall structure provides a portion of a leading edge of an airfoil section of an engine component.

11 . The article as recited in claim 1 , wherein the multi-layer wall structure includes at least one of an energy harvesting layer, a communications layer, and a computation layer.

12 . A method of forming an aircraft component, comprising:
embedding a sensor into a wall, the sensor bonded to the wall; and forming a portion of an aircraft component with the wall.

13 . The method as recited in claim 12 , wherein embedding step includes joining at least one layer of metallic material to the sensor.

14 . The method as recited in claim 13 , wherein the at least one layer of metallic material and the sensor are joined using an ultrasonic welding process.

15 . The method as recited in claim 12 , including shaping the wall to correspond to a portion of the aircraft component, the wall shaped to include a bend.

16 . The method as recited in claim 15 , wherein the wall provides a leading edge of the aircraft component.

17 . A method of forming an engine component, comprising:
additively forming a wall by bonding a plurality of metal layers together using an ultrasonic welding process; embedding a sensor into the wall by bonding the sensor to the metal layers during the additive forming step; and forming a portion of an engine component with the wall.

18 . The method as recited in claim 17 , wherein the metal layers include at least one of nickel (Ni), steel, cobalt (Co), and titanium (Ti).

19 . The method as recited in claim 17 , wherein each of the metal layers includes a plurality of pieces of material, wherein adjacent pieces of material establish a seam, and wherein the metal layers are arranged such that the seams of adjacent layers are staggered relative to one another.

20 . The method as recited in claim 17 , wherein the sensor is selected from the group consisting of optical fibers, pressure transducers, temperature sensors, position sensors, and strain gauges.

Assignees

• United Technologies Corp

Inventors

• Schmidt Wayde R
• Culp Slade R

Classifications

• B22F10/20

  Direct sintering or melting · CPC title

• G01K2205/00

  Application of thermometers in motors, e.g. of a vehicle · CPC title

• B32B15/18

  comprising iron or steel {(B32B15/011, B32B15/012 and B32B15/013 take precedence)} · CPC title

• B32B15/14

  next to a fibrous or filamentary layer · CPC title

• G01K1/14

  Supports; Fastening devices; Arrangements for mounting thermometers in particular locations · CPC title