Objective

Prove and demonstrate the new concept of sensor-integrated

“smart part” that can be easily installed in existing and new

energy systems for in situ monitoring of the health statues

of critical components and key operational parameters

under harsh conditions.

Novel Optical Carrier based Microwave Interferometry (CCMI)

Single crystal sapphire fiber Michelson OCMI sensor for high temperature and strain sensing. Excellent signal

quality, temperature measurement repeatability, and stability.

Assembly-Free Sensor Fabrication

Background

INTRODUCTION • Demands: Success of clean coal technologies will rely heavily on

sensors and instrumentation for: advanced process control/

optimization, Key components protection, System maintenance

and lifecycle management

• Requirements: Sensors need to survive and operate in the high-T,

high-P and corrosive/erosive harsh environments for a long of

time.

• Status: Current sensor and monitoring technologies capable of

operating in harsh conditions are extremely limited

Additive Manufacturing of Smart Parts

• Sensor-integrated smart parts: a new paradigm for

sensing in advanced energy systems

• Innovative approaches to tackle challenging problems • Robust sensors: The novel concept of OCMI and fs laser

assembly-free device fabrication

• Sensor embedment: Additive manufacturing

• Survivability: Transition layers between the sensor and host

• Dependable performance: Comprehensive thermal-mechanical

modeling/simulations of the “smart parts”

• Distributed sensing: Joint frequency-time domain method

uniquely enabled by mixing microwave with optics

• Demonstration: Tests and performance evaluations in simulated

laboratory conditions using existing facilities

Protective transition layers

Acknowledgement

DOE/NETL funding: DE-FE0012272, 10/01/2013 – 09/30/2016

Program manager: Richard Dunst

Technical POC: Hai Xiao, haix@clemson.edu, (864) 656-5912

Additive Manufacturing of Smart Parts with Embedded Sensors

for In-Situ Monitoring in Advanced Energy Systems Hai Xiao1, Xinwei Lan1, Jie Huang1, Ming C. Leu2, Hai-Lung Tsai2, and Junhang Dong3

1 Department of Electrical and Computer Engineering, the Center for Optical Materials Science and Engineering Technologies (COMSET), Clemson University

2 Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology

3 Department of Chemical Engineering, University of Cincinnati

Spatially continuous distributed strain measurement

using cascaded intrinsic Fabry-Perot OCMI sensors.

The spatial resolution can be as high as 1 cm. The

distance can be as long a few kilometers.

The essence of OCMI is to read optical interferometers in

microwave domain. the system offers many unique features

that are particularly advantageous for sensing applications

• High signal quality and excellent visibility

• Relieved requirement on fabrication

• Insensitive to the variations of polarization

• Low dependence on multimodal influences and can be

implemented in special optical fibers (e.g., multimode,

single crystal sapphire, polymer fibers) and free space

• Spatially continues distributed sensing with high

resolution

Dual-laser additive manufacturing of metal smart

parts

Summary

Additive manufacturing (AM) of ceramic smart parts based on freeze-form extrusion process

CURRENT TECHNOLOGIES AND LIMITATIONS

• Traditionally, sensors are attached to or installed onto the

component after the structure is fabricated

• Costly and complicated sensor packaging before installation

• Poor survivability and reliability of the sensors

• Discrepancy between the sensor reading and the actual status

• Potential performance compromise of the host

materials/structures

OPPORTUNITIES - SENSOR-EMBEDDED “SMART PARTS”

• Smart parts – widely used and proven successful in structural

health monitoring (SHM)

• Provide the real-time information on the component and system

• Reduce the complexity in sensor packaging and installation

• Increase the robustness and reliability of the system

Smart Parts

Distributed temperature, strain and pressure sensors embedded in the tube/pipe wall

Distributed pressure, temperature, and strain sensors embedded circumferentially in the tube/pipe wall

OCMI #3: Strain & crack detection

OCMI #1: Temperature & wall thinning

OCMI #2: Strain & crack detection

OCMI #4: temperature & wall thinning

z

y x

SMART PIPE SMART LINER

Scope of Work

• Robust, high-temperature tolerated, embeddable optical carrier

based microwave interfereometry (CCMI) sensors

• Novel signal processing and instrumentation for distributed sensing

• Comprehensive thermal and mechanical models for optimal sensor

embedment and rational interpretation of the sensor outputs

• Multifunctional protective layers between the sensor and the host

for thermal, mechanical and chemical protection of the sensors

• Additive manufacturing of the “smart parts”

• Feasibility tests and performance evaluation

Path 1

Path 2

Control

Intensity

Modulator

Optical broadband

source

Δλ

High-speed optical detection

Frequency

scanning

Sync

Optical interferometer

Microwave source Vector microwave

detector

Data acquisition

(c) Propagation delay

+ Fourier

transform

OPD

2 1 22 cos2

O OL LA M

c

1 22

2

O OW L L

c

(a) Amplitude spectrum (b) Phase spectrum W+LO1 W+LO2

High speed

Photodetector

030

6090

120 0

10

20

0

0.5

1

1.5

2

2.5

3

x 10-3

Deflectio

n (mm)

Axial location (cm)

str

ain

Measurement data

Axi

al s

trai

n

Apply complex Fourier Transform on the window-gated data to reconstruct the interferogram of Section 8

Fibre core

(9 m in diameter)

Push

IFPI 1 IFPI 5 IFPI 2 IFPI 4 IFPI 8 IFPI 3 IFPI 6 IFPI 7 IFPI 9

L

Cascaded OCMI-IFPI sensor epoxied on the beam

Aluminum cantilever beam

(e)

(a)

Fs laser inscribed reflector

(d)

1423 1462 1500 1538 1577

0.0

0.2

0.4

0.7

0.9

1.1

1.3

1.6

Ref

lect

ion

(mU

nit)

Distance (cm)

Time gating window to isolate Section 8 (b)

500 1000 1500 2000 2500 3000

-90

-85

-80

-75

-70

-65

-60

Am

pli

tude

(dB

)

Frequency (MHz)

(c)

(a)

(b)

(c)

(d) (e) (f)

Joint by fusion

R1

3dB multimode

fiber coupler Input

Output

Joint by fusion

R2

10.2 cm

Silica graded-index multimode

(62.5 m core and 125 m

cladding) Single crystal sapphire fiber (125

m diameter, uncladded)

1000 1500 2000 2500 3000 3500 4000 4500

-60

-50

-40

-30

Am

plit

ude

(dB

)

Frequency (MHz)0 200 400 600 800 1000

4090

4100

4110

4120

4130

4140

Increasing

Decreasing

Res

onan

t fr

equen

cy (

MH

z)

Temperature (C)

Slope 0.044 MHz/C

1840 1850 1860 1870 1880 1890

4092.50

4092.60

4092.70

4092.80

Res

on

ant

freq

uen

cy (

MH

z)

Time (minutes)

1000C, with a standard deviation of 2.7C

20 μm

125 m

75 m

Silica fiber pressure sensor Sapphire fiber EFPI

sensor

Silica fiber temperature sensor Sapphire fiber grating

20 μm 20 μm

(a) (b)

Core (9m in diameter)

Fs laser inscribed reflector (15m × 40m)

Silica fiber IFPI sensor

Femtosecond laser micromachining

YLR-100 laser/

YLR-1000 laser Galvo

Laser coupler Beam expanderOptical fiber

F-θ lens

Working planeLaser

controller

UV nanosecond

laser

Beam expanderHalf wave

plate

Powder bed

Dichroic

Mirror

Motion stage

Z axis

Focusing lens

Motion stage

X-Y axis

Co-axial gas nozzle

Sapphire/Quartz fiber/rod

Dense

cladding

Sintered porous

layer of cladding

Dense metal

layer

(Porous) ceramic

adhesion

Host

component

T

i

A

l

M

g

O

Multiple layers of coatings to interface the embedded sensor

and the host and to provide the chemical, thermal,

mechanical and optical protections of the embedded sensors.

MgAl2O4-Ti0.98Pd0.2 - 1000oC