Composite Coating-Based Heat Flux Sensor for In Situ Heat Flux Monitoring of Hot-End Components

IF 4.3 2区 综合性期刊 Q1 ENGINEERING, ELECTRICAL & ELECTRONIC
Chenhe Shao;Fuxin Zhao;Peng Zhang;Ye Qiao;Yanzhang Fu;Yuelong Li;Yingjun Zeng;Lida Xu;Lanlan Li;Gonghan He;Songyue Chen;Daoheng Sun;Qinnan Chen
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Abstract

The control of thermal energy during the operation of aeroengine turbine blades in extreme environments is crucial for the reliability of the associated equipment. Among the key parameters influencing thermal energy transfer, heat flux density plays a significant role. The development of heat flux sensors on the surface of turbine blades enables real-time measurement of these critical parameters. However, extreme conditions of high temperature and pressure present challenges, such as the tendency for surface coatings on turbine blades to peel off and for insulation properties to degrade. To address these issues, we propose a composite process for the in situ preparation of high-temperature heat flux sensors. The composite gradient coating, applied via plasma spraying, ensures the reliability of the coating and enhances its insulating properties, with the insulation resistance reaching 20 k $\Omega $ at a high temperature of 1100 °C. Additionally, curved, conformal high-temperature thin-film sensitive layer electrodes and thermal resistive layers are prepared in situ on the coating surface using physical vapor deposition (PVD). This method, characterized by nonintrusive flow and conformality, enables the measurement of heat flux up to 1.9 MW/m2, with a measurement error of less than ±2.5% FS. The proposed approach offers a feasible solution for the real-time monitoring of heat flux density parameters on blade surfaces in extreme environments.
热端元件现场热流监测用复合涂层热流传感器
在极端环境下,航空发动机涡轮叶片运行过程中的热能控制对相关设备的可靠性至关重要。在影响传热的关键参数中,热流密度起着重要的作用。涡轮叶片表面热流密度传感器的发展使这些关键参数的实时测量成为可能。然而,高温高压的极端条件也带来了挑战,例如涡轮叶片表面涂层有脱落和绝缘性能下降的趋势。为了解决这些问题,我们提出了一种原位制备高温热流通量传感器的复合工艺。采用等离子喷涂的复合梯度涂层确保了涂层的可靠性,增强了其绝缘性能,在1100℃高温下的绝缘电阻达到20 k $\Omega $。此外,利用物理气相沉积(PVD)在涂层表面原位制备了弯曲的、共形的高温薄膜敏感层电极和热阻层。该方法具有非侵入性流动和一致性的特点,可以测量高达1.9 MW/m2的热流密度,测量误差小于±2.5% FS。该方法为极端环境下叶片表面热流密度参数的实时监测提供了可行的解决方案。
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来源期刊
IEEE Sensors Journal
IEEE Sensors Journal 工程技术-工程:电子与电气
CiteScore
7.70
自引率
14.00%
发文量
2058
审稿时长
5.2 months
期刊介绍: The fields of interest of the IEEE Sensors Journal are the theory, design , fabrication, manufacturing and applications of devices for sensing and transducing physical, chemical and biological phenomena, with emphasis on the electronics and physics aspect of sensors and integrated sensors-actuators. IEEE Sensors Journal deals with the following: -Sensor Phenomenology, Modelling, and Evaluation -Sensor Materials, Processing, and Fabrication -Chemical and Gas Sensors -Microfluidics and Biosensors -Optical Sensors -Physical Sensors: Temperature, Mechanical, Magnetic, and others -Acoustic and Ultrasonic Sensors -Sensor Packaging -Sensor Networks -Sensor Applications -Sensor Systems: Signals, Processing, and Interfaces -Actuators and Sensor Power Systems -Sensor Signal Processing for high precision and stability (amplification, filtering, linearization, modulation/demodulation) and under harsh conditions (EMC, radiation, humidity, temperature); energy consumption/harvesting -Sensor Data Processing (soft computing with sensor data, e.g., pattern recognition, machine learning, evolutionary computation; sensor data fusion, processing of wave e.g., electromagnetic and acoustic; and non-wave, e.g., chemical, gravity, particle, thermal, radiative and non-radiative sensor data, detection, estimation and classification based on sensor data) -Sensors in Industrial Practice
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