Integration of Sensors through Additive Manufacturing Leading to Increased Efficiencies of Gas Turbines for Power Generation and Propulsion

Sponsor: ARPA-E

Collaborators: Georgia Tech, CVD Mesoscribe, Raytheon Technologies Research Center, Pratt & Whitney, Siemens

Printed components using metal additive manufacturing with integrated sensors open up new opportunities for increasing efficiencies in complex energy systems. Most particularly, gas turbine based systems will be the most commonly utilized approach for the rapidly growing areas of electrical energy production and propulsion of aircraft for passenger and cargo transportation. Gas turbine manufacturers are embracing additively manufactured parts to increase the speed at which engines are developed and for use in the field for higher efficiencies. The most pressing question is whether these parts can withstand the harsh operational environments in the “hot sections”. With real-time sensing integrated into fielded devices using additive manufacturing, turbine manufacturers will realize 30-50% acceleration in product deployment of high efficiency components due to a faster reduction in component risk assessment, higher component efficiencies, and better reliability. The proposed effort will develop a path that provides an integrated approach for placing sensors into complex turbine components operated in extreme environments.