TY - JOUR

T1 - Degeneration Effects of Thin-Film Sensors after Critical Load Conditions of Machine Components

AU - Ottermann, Rico

AU - Steppeler, Tobias

AU - Dencker, Folke

AU - Wurz, Marc Christopher

N1 - Funding Information: The authors thank the German Research Foundation (DFG) that funded this work within the research project “Integrated sensors for intelligent large-diameter bearings” (WU 558/41-1) as part of the Priority Program 2305 “Sensor-integrating machine elements”.

PY - 2022/9/27

Y1 - 2022/9/27

N2 - In the context of intelligent components in industrial applications in the automotive, energy or construction sector, sensor monitoring is crucial for security issues and to avoid long and costly downtimes. This article discusses component-inherent thin-film sensors for this purpose, which, in contrast to conventional sensor technology, can be applied inseparably onto the component’s surface via sputtering, so that a maximum of information about the component’s condition can be generated, especially regarding deformation. This article examines whether the sensors can continue to generate reliable measurement data even after critical component loads have been applied. This extends their field of use concerning plastic deformation behavior. Therefore, any change in sensor properties is necessary for ongoing elastic strain measurements. These novel fundamentals are established for thin-film constantan strain gauges and platinum temperature sensors on steel substrates. In general, a k-factor decrease and an increase in the temperature coefficient of resistance with increasing plastic deformation could be observed until a sensor failure above 0.5% plastic deformation (constantan) occurred (1.3% for platinum). Knowing these values makes it possible to continue measuring elastic strains after critical load conditions on a machine component in terms of plastic deformation. Additionally, a method of sensor-data fusion for the clear determination of plastic deformation and temperature change is presented.

AB - In the context of intelligent components in industrial applications in the automotive, energy or construction sector, sensor monitoring is crucial for security issues and to avoid long and costly downtimes. This article discusses component-inherent thin-film sensors for this purpose, which, in contrast to conventional sensor technology, can be applied inseparably onto the component’s surface via sputtering, so that a maximum of information about the component’s condition can be generated, especially regarding deformation. This article examines whether the sensors can continue to generate reliable measurement data even after critical component loads have been applied. This extends their field of use concerning plastic deformation behavior. Therefore, any change in sensor properties is necessary for ongoing elastic strain measurements. These novel fundamentals are established for thin-film constantan strain gauges and platinum temperature sensors on steel substrates. In general, a k-factor decrease and an increase in the temperature coefficient of resistance with increasing plastic deformation could be observed until a sensor failure above 0.5% plastic deformation (constantan) occurred (1.3% for platinum). Knowing these values makes it possible to continue measuring elastic strains after critical load conditions on a machine component in terms of plastic deformation. Additionally, a method of sensor-data fusion for the clear determination of plastic deformation and temperature change is presented.

KW - bearings

KW - k-factor

KW - plastic deformation

KW - sensor data fusion

KW - sputtering

KW - strain gauge

KW - temperature coefficient of resistance

KW - temperature sensor

KW - thin-film sensor

KW - tribological contact

UR - http://www.scopus.com/inward/record.url?scp=85140926439&partnerID=8YFLogxK

U2 - 10.3390/machines10100870

DO - 10.3390/machines10100870

M3 - Article

AN - SCOPUS:85140926439

VL - 10

JO - Machines

JF - Machines

IS - 10

M1 - 870

ER -