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Assembly Methods for Sensors in Harsh Environments

Project Code: 0905-09


Produce a review of sensor technology for harsh applications, elf-powered systems and wireless communications, assembly methods and reliability assessment methods required. Within this review to confirm the priority topics for practical evaluation and development.

Demonstrate the benefits and relative merits of precision laser welding, friction stir welding, direct ceramic to metal bonding in the fabrication of key structures for sensors and their attachment.

Define and perform reliability tests on test vehicles produced to demonstrate the assembly techniques.

Project Outline

Review of sensor technology for harsh environments:

a. Sensors (with special reference to HT PEs)

b. Local power generation

c. High reliability attachment to target structures

Identification of standards, both existing and still required for lifetime assessment

Design of test vehicles to demonstrate assembly properties and reliability

Fabrication and assembly of test vehicles using precision technologies

a. Precision laser welding

b. Micro friction stir welding metallics and polymers

c. Direct ceramic/metal bonding

Test of assemblies

a. Mechanical properties

b. Cyclic thermal fatigue

Reporting and dissemination


Relevant Industry Sectors

Oil and Gas, Power Generation, Sensors and Electronics, Automotive, Aerospace

Technical and Economic Benefits

Permit fabrication of novel sensors and their supplementary systems.

Improved performance of thermal structures required for efficiency of sensor operation.

Improved lifetime and reliability of assemblies to target structures.

Position TWI precision assembly technology for renewables.


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