Dong Helei, Lu Meimei, Wang Weifeng, Tan Qiulin
School of Instrument and Electronics, North University of China, 030051 Taiyuan, China.
Key Laboratory of Micro/nano Devices and Systems, Ministry of Education, North University of China, 030051 Taiyuan, China.
Microsyst Nanoeng. 2024 Jul 25;10:105. doi: 10.1038/s41378-024-00748-8. eCollection 2024.
Hypersonic vehicles and aircraft engine blades face complex and harsh environments such as high heat flow density and high temperature, and they are generally narrow curved spaces, making it impossible to actually install them for testing. Thin-film heat flux sensors (HFSs) have the advantages of small size, fast response, and in-situ fabrication, but they are prone to reach thermal equilibrium and thus fail during testing. In our manuscript, an ITO-InO thick film heat flux sensor (HFS) is designed, and a high-temperature heat flux test system is built to simulate the working condition of a blade subjected to heat flow impact. The simulation and test results show that the test performance of the thick-film HFS is improved by optimizing the structure and parameters. Under the condition of no water cooling, the designed HFS can realize short-time heat flux monitoring at 1450 °C and long-term stable monitoring at 1300 °C and below. With a maximum output thermopotential of 17.8 mV and an average test sensitivity of 0.035 mV/(kW/m), the designed HFS has superior high-temperature resistance that cannot be achieved by other existing thin (thick) film HFSs. Therefore, the designed HFS has great potential for application in harsh environments such as aerospace, weaponry, and industrial metallurgy.
高超音速飞行器和航空发动机叶片面临着诸如高热流密度和高温等复杂而恶劣的环境，并且它们通常是狭窄的弯曲空间，这使得无法实际安装它们进行测试。薄膜热流传感器（HFSs）具有尺寸小、响应快和原位制造等优点，但它们在测试过程中容易达到热平衡从而失效。在我们的论文中，设计了一种ITO-InO厚膜热流传感器（HFS），并构建了一个高温热流测试系统来模拟叶片受到热流冲击的工作条件。模拟和测试结果表明，通过优化结构和参数，厚膜HFS的测试性能得到了提高。在无水冷却的条件下，所设计的HFS能够在1450 °C实现短时热流监测，在1300 °C及以下实现长期稳定监测。所设计的HFS最大输出热势为17.8 mV，平均测试灵敏度为0.035 mV/(kW/m)，具有其他现有薄（厚）膜HFS无法实现的卓越耐高温性能。因此，所设计的HFS在航空航天、武器装备和工业冶金等恶劣环境中具有巨大的应用潜力。
