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–In 2 O 3 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 2 ), 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.
High-temperature heat flux sensors play a pivotal role in detecting the dynamic heat exchange processes of heating and cooling, in high-temperature environments. However, the detection of surface heat flux on curved parts operating at high temperatures remains a formidable challenge. Flexible thin-film heat flux sensors, while offering benefits such as conformal adhesion and excellent portability, are typically limited by low operational temperatures and narrow measurement ranges. This work proposes a high-temperature flexible heat flux sensor based on multi-layered high-temperature resistant ceramics nanofibre membranes that one layer worked as a substrate and the other two work as thermal resistance layers, and direct ink writing platinum sensitive elements with Wheatstone Bridge configuration. The prototype sensor is capable of quantifying heat flux reaching 1330 kW/m 2 and withstands temperature as high as 1200 °C. The sensor is bendable with resistance change only about 0.5 % even when the bending radius was larger than 10 mm. These extraordinary characteristics indicate that such methodology will offer a new way for the development of high-temperature thin-film flexible heat flux sensors, demonstrating considerable potential for applications in high-temperature environments.
危险品化学品经营许可证（带存储）