Embedded active sensors for non-invasive material/process characterisation in extreme conditions
A high-temperature ultrasonic reflectometry system for real-time material property characterization during curing, using cost-effective bismuth titanate transducers.
Overview
This cutting-edge solution involves the use of embedded active sensors to characterize material properties in high-temperature environments. The core innovation lies in the cost-effective proprietary transducers, which are designed to function at temperatures up to 500 degrees Celsius and beyond. These transducers are integrated into components and process assemblies to monitor fluid and material properties such as temperature, density, viscosity, solidification, porosity and more, offering real-time insights during the curing process.
Technical specifications
- Operational Temperature: Capable of continuous operation at temperatures up to 500°C
- Cost Efficiency: Each sensing element costs as low as $15 USD
- Real-time Data Processing: Advanced edge algorithms to extract critical material properties
Technology readiness level
This technology is currently at a Technology Readiness Level of 4, having undergone various tests with process materials. Future plans include stakeholder engagement, lab and field testing with trial transducer arrays, and integration of wireless communication systems. These steps are designed to further validate and enhance the system's robustness and applicability in real-world conditions.
About Peak to Peak Measurement Solutions Ltd.
Peak to Peak Measurement Solutions Ltd. develops and supplies advanced embedded sensor technologies designed for the measurement and monitoring of dynamic machine elements. The company specializes in utilizing micro-ultrasonic transducers, which are permanently embedded into materials or interfaces to capture real-time data streams. By combining these specialized hardware sensors with tailored algorithms and edge-processing capabilities, the company provides actionable insights into system conditions. Their technology is distinct for its focus on ultrasonic reflectometry, an approach that allows for high-accuracy monitoring—such as measuring contact pressure, wear, stress, and lubricant film thickness—without the destructive or slow processes often associated with traditional methods.
These solutions are critical for industrial and academic partners looking to optimize equipment performance, improve maintenance strategies, and support net-zero initiatives through digitalization. The company works across various sectors, including rail, automotive, and mechanical engineering, providing bespoke equipment and consultancy services that bridge the gap between cutting-edge research and industrial application. Their systems have been deployed in demanding environments, such as high-speed rail monitoring, and they have successfully collaborated with various research organizations and partners to deliver specialized measurement solutions for complex mechanical challenges.
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