Harsh-environment fiber optic sensors for structural monitoring applications

The objective of the work presented was to develop a suite of sensors for use in high-temperature aerospace environments, including turbine engine monitoring, hypersonic vehicle skin friction measurements, and support ground and flight test operations. A fiber optic sensor platform was used to construct the sensor suite. Successful laboratory demonstrations include calibration of a pressure sensor to 100psi at a gas temperature of 800degreesC, calibration of an accelerometer to 2.5g at a substrate temperature of 850degreesC. Temperature sensors have been field tested up to 1400degreesC, and a skin friction sensor designed for 870degreesC operation has been constructed. The key advancement that enabled the operation of these novel harsh environment sensors was a fiber optic packaging methodology that allowed the coupling of alumina and sapphire transducer components, optical fiber, and high-temperature alloy housing materials. The basic operation of the sensors and early experimental results are presented. Each of the sensors described here represent a quantifiable advancement in the state of the art in high-temperature physical sensors and will have a significant impact on the aerospace propulsion instrumentation industry.