To meet the NASA need for measurement of pressure, temperature, and strain in high temperature and/or harsh environment to support rocket propulsion systems ground test, RC Integrated Systems LLC (RISL) proposes to develop a novel Hybrid Additive Manufacturing of Integrated Sensing (HAMIS) System, providing high-resolution simultaneous measurement of pressure, temperature, and strain in high temperature and/or radiation environment. HAMIS is based on additive manufacturing (AM) of passive wireless sensors using high-temperature refractory materials, capable of being bonded to the inner surface of high temperature gas pipes to measure temperature, pressure, and strain. HAMIS sensors can withstand temperatures up to 5000 degrees F. AM approach enables flexible fabrication of miniature (4 mm by 4 mm by 0.8 mm) sensors. In Phase I, RISL will identify sensor types, number, placement, connectivity, and data handling and processing; determine processes and procedures for sensor manufacturing, insertion, and emplacement; demonstrate its feasibility through modeling; RISL will also develop a breadboard system to demonstrate the HAMIS concept. In Phase II, RISL will develop a HAMIS prototype with representative sensors of each type and test each under simulated laboratory conditions with the goal to achieve technology readiness level (TRL)-5.
HAMIS can be incorporated into Stennis Space Center (SSC) rocket ground test facility to enhance Chemical and Advanced Propulsion technology development and certification. The HAMIS system can also be incorporated into SSC’s Nuclear Thermal Propulsion Ground Test Exhaust Capture System for measurement of engine exhaust gas temperature and pressure. This development will support multiple NASA missions including human mission to Mars.
The proposed sensors can be used for applications including oil, gas, and geothermal well drilling and production, as well as CO2 gas sequestration. Other applications include monitoring gas temperature and pressure in turbine engine in coal-fired power plants, natural-gas-based power plants, geothermal plants, as well as other power-generation facilities throughout the nation.