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TurboTrack

Case Study

Wireless Turbine Blade Monitoring for the U.S. Air Force – From SBIR to Scalable Aerospace Innovation

Client: Sensatek Propulsion Technology, Inc.
Program: U.S. Air Force / AFWERX SBIR
Application: Wireless Passive Temperature Sensors for Helicopter Turbine Blades
Use Case: T53 Turboshaft Engine Testing and Commercial Engine Health Monitoring

Challenge

Turbine blades in helicopters operate under extreme conditions—temperatures exceeding 850°C, rotation speeds over 16,000 RPM, and g-forces of 45,000g. Traditional wired sensors can’t withstand this environment and pose significant limitations in cost, data latency, and maintenance downtime.

The Air Force needed a non-intrusive, real-time, and survivable monitoring solution for turbine blade temperature and potential structural strain during engine operation.

Innovation

Sensatek developed and successfully tested a wireless passive RF sensor system using polymer-derived ceramics (PDCs) and platinum metallization. The system comprises:

  • Passive wireless sensors tack-welded onto turbine blades
  • High-temperature coaxial slot antennas for non-contact signal capture
  • Real-time data acquisition via Sensatek's proprietary Turbotrack software

This system reads the temperature from rotating blades up to 1,070°C, withstanding high-speed rotation and vibration without requiring a slip ring or external cooling.

Commercialization Services Delivered

End-to-End System Design & Engineering:

Developed, tested, and refined full sensing chain—sensor, antenna, signal conditioning, and software GUI.

Testing & Validation under Real Conditions:

System validated through multiple full-speed runs in a T53 test cell at Embry-Riddle Aeronautical University. All 14 Air Force-defined requirements (e.g., temperature accuracy, survivability, signal stability) were met or exceeded.

Material Selection & Bonding Strategy Optimization:

Tack-welding proved superior to brazing and flame-spraying, with sensors surviving over 1 hour of continuous high-temperature testing.

Simulation-Driven Commercialization:

Performed CFD and FEA simulations to assess impact on airflow, heat transfer, and structural vibration—critical for certifying deployability on rotating engine components.

Dual-Use Readiness:

Sensors and software were customized for both defense (e.g., T53, J85 engines) and commercial aerospace/energy turbines (e.g., Siemens, GE, Rolls-Royce gas turbines).

Outcomes

Sensatek developed and successfully tested a wireless passive RF sensor system using polymer-derived ceramics (PDCs) and platinum metallization. The system comprises:

  • Exceeded sensor survivability and precision goals at >850°C and 16,000 RPM
  • Demonstrated real-time monitoring capability without engine disassembly
  • Validated over 10 key technical parameters including vibration resistance, software GUI performance, and multi-sensor interrogation
  • Filed multiple patents for RF-based sensing in harsh environments
  • Created a path for scalable production using flame-spray deposition for curved turbine blade integration

Impact Statement

“Sensatek’s breakthrough in passive wireless temperature sensing for rotating engine parts gives the Air Force a mission-ready, high-temperature sensing solution. With full system integration and real-time analytics, this technology sets the stage for predictive maintenance and autonomous engine health monitoring.”

— AFWERX Program Evaluator