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In a Q&A session, Sensor Coating Systems’ managing director, Dr Jörg Feist discusses the company’s novel high-definition thermal mapping service for temperature detection on mission-critical aero engine components.

In a Q&A session, Sensor Coating Systems’ managing director, Dr Jörg Feist discusses the company’s novel high-definition thermal mapping service for temperature detection on mission-critical aero engine components.

Sensor Coating Systems (SCS) provides a high-temperature measurement service and generates digital temperature maps on customers’ CAD drawings and the 3D data. The award-winning technology enables accurate temperature detection, which assists in improving and optimising the operation of machinery, lowering fuel costs, maintaining the integrity and reducing carbon emissions. It is based on memory materials for engineering applications in demanding or inaccessible environments, allowing measurement of coated or painted hot gas path components, such as aero engine turbine blades and nozzle guide vanes, among others. SCS is a post-revenue company, but started off as a university spin-out from Imperial College London. Eight years later and SCS works with the biggest names in power generation, jet propulsion and automotive and also with NASA.

SCS’ thermal history paint process is used for lower temperature ranges between 150°C to 900°C

Q) What are the current surface technology challenges that face aero engine OEM manufacturers?

The efficiency of an aero engine depends on the firing temperature. The higher the firing temperature, the higher the efficiency. However, when operating an engine today the combustion gas firing temperatures can be higher than the melting point of the metals. Consequently, the components need to be cooled down again using air from the compressor. This in turn will decrease efficiency and hence it needs to be fine-tuned and optimised to have a net efficiency gain.

For this to be successful, the US Propulsion Instrumentation Working Group (PIWG) says that the temperature of 80% of the surface of a hot section component needs to be known. Also, very high surface temperatures above 1,500°C cannot be measured across large surface areas inside an engine.

Q) Tell me more about your processes and any environmental aspects?

Our coating is not about protection. Our coating measures past temperatures. It is a ‘temperature memory material’. The application with APS atmospheric plasma spraying enables the coating to stay on the engine component for several hundred or thousands of hours in extreme combustion environments.

However, most of the time customers use it for shorter duration engine development tests from less than an hour to several tens of hours. The measurement range for these thermal history coatings (THC) can range from 500°C to 1,500°C and beyond. We also have a thermal history paint (THP) version which can be applied for lower temperature ranges between 150°C to 900°C. This also works well with turbocharger turbines and was demonstrated.

SCS is currently developing a high temperature coating which can measure temperatures potentially up to 1,600°C and above. Tests carried out in cooperation with NASA have shown good compatibility with the latest material developments for new generation engines. The research was published in September 2020 at the ASME Turbo Expo.

Q) Can you share any success stories of programmes that you are working on?

SCS has successful developed its technology under the UK’s National Aerospace Technology Programme (NATEP), which requires the participation of end users. This led to SCS working with Pratt & Whitney during the programme, but also with power generation companies such as MAN Energy Solutions. SCS currently has three international aerospace manufacturers as clients and all have decided to engage in development programmes with us.

Q) What kinds of rigorous testing procedures do your processed parts undergo to ensure they pass airworthy regulations?

The technology does not need to be tested on airworthiness yet as it is used exclusively for engine development programmes at the moment. If in the future the technology is used for service and maintenance operations, airworthiness tests will be needed. Currently, the technology undergoes validation testing in laboratories and in engine tests.

SCS can generate digital temperature maps on customers’ CAD drawings and 3D data

Q) What developments do you see happening in the construction and surface protection of aero engines?

The move to Net Carbon Zero will force the aviation industry to use hydrogen-based fuels in particular for long distance flights. This requires potentially redesign of engines and also the combustion systems. This will place SCS into a good position when it comes to rapid temperature profiling of new engine designs.

Q) Is it difficult to do business in the aerospace sector, considering the safety regulations, accreditations and certifications you need to satisfy?

As SCS operates in the development arena it is much easier. Flight safety regulations are not applicable. Civil aviation has suffered significantly through the Covid-19 pandemic and we have seen some projects being moved backwards, but not cancelled! In contrast our clients see the necessity to employ cutting edge technology to deliver the engines of tomorrow and made decisions to contract with us in 2021.

Q) Is there a particular area of your business that has been hit by the pandemic?

Yes, our employees haven’t been furloughed, but are increasingly working from home. After nine months of pandemic this wears people out. General fatigue is visible; however project work has not stopped and everybody is giving their best to cope with the situation. Supply chain partners stopped working and this jeopardised continuity of contract work. Universities closed facilities and relevant R&D work was interrupted. Significant governmental support came through Innovate UK. Live projects were supported, but there was chaos regarding the changing of rules.

Q) Where to next for your company?

Commercially we have strengthened our marketing team with an ex-Rolls-Royce temperature measurement expert. He strongly believes in SCS’s unique technology and joined our team in November 2020. Together we will strengthen our export orientated business even further and reach out to new customers in the US, Europe and South-East Asia.

Technically we have applied for additional research funding to make the next game-changing step: snake robotics. We have gathered industrial support from companies in the US and Europe to perform ‘on-engine’ diagnostics using robotics and deep learning technologies. If granted and successful, the company will partner with one of the robotic hubs in London and could provide rapid temperature scanning ‘on-engine’ test beds in record times, assisting in quick market entries for new efficient engines.

www.sensorcoatings.com

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