Wireless Networked, High Temperature, Wide Bandwidth Pressure Sensors for Propulsion System Monitoring

This NASA Phase II STTR program would develop wireless networked, high temperature, wide bandwidth pressure sensors for use in propulsion systems during ground test and launch operations. Both applications require broadband and in particular high frequency response for adequate diagnostics, and operation at very high temperatures in rocket engine environments. The team proposes major changes in pressure sensor fabrication and implementation to allow order of magnitude increases in their temperature range, from their current 250 C upper temperature limit to 1000 C and above. Such modifications involve 1) improved packaging processes to reach approximately 500 C continuously, 2) the use of very high temperature polymer-derived ceramic thermal barrier materials to reach 1000 C intermittently, and 3) the optimization of wide bandwidth frequency response of DC to above 5MHz with thermal barrier materials. The team will transition the wireless networked, high temperature, high frequency pressure sensors from their current concept to prototype stage products of use for rocket engine applications. This program will develop wireless networked, high temperature, wide bandwidth pressure sensors for use in propulsion systems during ground test and launch operations. Both applications require broadband and in particular high frequency response for adequate diagnostics, and operation at very high temperatures in rocket engine environments. The team proposes major changes in pressure sensor fabrication and implementation to allow order of magnitude increases in their temperature range to 1000 °C and above. The team will fabricate patterned two-dimensional sensor arrays and internal electronics using optimized materials. The team will perform a complete analysis of sensor cross-sensitivities and noise sources to allow optimization of signal-to-noise ratio and practical sensor sensitivity. The proposed wireless interconnection allows data from a single high temperature pressure sensor to be transmitted to a cell phone or tablet, or data from multiple probes to be transmitted to a fixed central electronic unit that can communicate data to engineers via the web.  The overall technical objective of the proposed NASA program is to transition the wireless networked, high temperature, wide bandwidth pressure sensors for use in propulsion system from their current concept to prototype stage products of use to NASA’s ground test and launch facilities. The team will be ready for the possibility of testing our propulsion sensors in NASA facilities. Phase II deliverables are: • Periodic technical summary reports, as required • Testing at Virginia Tech for durability evaluation of high temperature pressure sensors, prior to month 6 • Testing at Virginia Tech for durability evaluation of high temperature pressure sensors, prior to month 12 • Piggyback testing of high temperature pressure sensors on-site at NASA, prior to month 18 • Final high temperature pressure sensors and data interface, month 24 • Final report, month 24

The proposed wireless networked, high temperature, wide bandwidth pressure sensors can be used in the propulsion systems during ground test and launch operations. Currently, there are no commercial pressure sensors that can cover the wide frequency bandwidth from DC to 5MHz, even without high temperature capacities. The advantage of the proposed sensors over these existing low temperature products is their DC to 5MHz frequency response. Primary customers would be university, government laboratory and industry researchers. Customers for wireless networked, high temperature, high frequency pressure transducers will be the manufacturers of engines and of high-speed vehicle and flight control system designers and manufacturers Broader commercial sensor opportunities include oil and gas down-hole measurements.

This is early/mid-stage (TRL 6) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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