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Direct Write Thermal Spraying of MesoscaleElectronics and Sensor Structures
Novel Approaches to Integrating Sensors on Structures
S.Sampath, R.Gambino, J.Longtin and H.HermanCenter for Thermal Spray Research
Department of Materials Science and EngineeringState University of New York
Stony Brook, NY 11733
R.GreenlawIntegrated Coating Solutions
Huntington Beach, CA
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
Al2O3
Ni
Graded
Thermal Spray Direct Write Deposition CapabilitiesRange 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 forharsh 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
5050 ? mmAlumina
Permalloy
Antenna on ConcreteWith Polymer overcoat
Mesoscale Direct Write Capability
Height ~ 60 ? mBase Diameter ~ 350 ? m
Height ~ 60 ? mBase Diameter ~ 350 ? m
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 thermocoupleBy direct write
- chromel/constantan- up to 900+ °C- high sensitivity
(> 45 mV/°C) - High reproducibility
NiCu NiCrAluminacoating 0 200 400 600 800 1000 1200
0
10
20
30
40
50
K-type thermocouple
Seebeck coefficientS = 41.7 ?V / °C
Vol
tage
(mV
)
Temperature (°C)
K-type thermocoupleBy direct write
- chromel/alumel- up to 1200+ °C- good sensitivity - robust performance
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 oC• Embedded TC: 435 oC
substrate
thermocouple
YSZ TBC
0 40 80 120 160 200 2400
2
4
6
8
10
12
bare coated (6 mils)
S ~ 43 ? V/deg
Thermocouple K-type
Vol
tage
(m
V)
Temperature (oC)
0
100
200
300
400
500
600
700
800
900
1000
0 1 2 3 4 5 6 7 8 9
Time (minutes)
Tem
per
atu
re (
oC
)
11in
9in
7in
0
100
200
300
400
500
600
700
800
900
1000
0 1 2 3 4 5 6 7 8 9
Time (minutes)
Tem
per
atu
re (
oC
)
11in
9in
7in
Response as a function of standoff distance
Embedded Strain Gauge and Other DevicesEmbedded Strain Gauge and Other Devices
MICEstrain gauges
Commercialstrain gauge
Strain, ? (x10-6)
-250 -200 -150 -100 -50 0 50 100 150 200 250
Res
ista
nce
chan
ge, ?
R/R
(x1
0-6)
-500
-400
-300
-200
-100
0
100
200
300
400
500Commercial SG, GF=2.085Laser-cut SG-load, GF=1.328Laser-cut SG-unload, GF=1.322
• Good repeatability• Good linearity• Negligible hysterisis
= Si= Si= Ni= Ni
15 mm
3 mm
13 mm
3 mm
Prim
ary
Secondary
Prim
ary
Secondary
Inductors/Transformers
Thermistors RF ElementsMagnetic Sensors Microheaters
Applications in a wide range of industries
Aerospace Automotive
Dental Implants/ProstheticsPaper, Textile & Printing Industry
Infrastructure
Mesoscale Electronics and Sensors
Thermal Spray MICE allows sensor integration onto variety of structures embedded within structural coatings
Conformal Direct Write Capability(Prototype Tool and System)
Possible Direct-writtenmultisensor configuration
on a turbine blade
Conformal direct Write cell
Direct write antennaOn helmet
FeedstockDelivery
Diagnostics
Integrationand Control
Motion
Powder Feed
Deposition
WaterCooling
PowerSupply
Gas
Stony Brook Prototype Direct Write Tool
Fine FeatureDevelopment
Vision
Powder Feed