Rapid Printing of High-Temperature Polymer-Derived Ceramic Composite Thin-Film Thermistor with Laser Pyrolysis

Abstract

Polymer-derived ceramic (PDC)-based high-temperature thin-film sensors (HTTFSs) exhibit promising applications in the condition monitoring of critical components in aerospace. However, fabricating PDC-based HTTFS integrated with high-efficiency, high-temperature anti-oxidation, and customized patterns remains challenging. In this work, we introduce a rapid and flexible selecting laser pyrolysis combined with a direct ink writing process to print double-layer high-temperature antioxidant PDC composite thin-film thermistors under ambient conditions. The sensitive layer (SL) was directly written on an insulating substrate with excellent conductivity by laser-induced graphitization. Then, the antioxidant layer (AOL) was written on the surface of the SL to realize the integrated manufacturing of double-functional layers. Through characterization analysis, it was shown that B2O3 and SiO2 glass phases generated by the PDC composite AOL could effectively prevent oxygen intrusion. Therefore, the fabricated PDC composite thermistors exhibited a negative temperature coefficient in the temperature range from 100 to 1100 °C and high repeatability below 800 °C. Meanwhile, it has excellent high-temperature stability at 800 °C with a resistance change of only 2.4% in 2 h. Furthermore, the high-temperature electrical behavior of the thermistor was analyzed. The temperature dependence of the conductivity for this thermistor has shown an agreement with the Mott’s variable range hopping mechanism. Additionally, the thermistor was fabricated on the surface of an aero-engine blade to verify its feasibility below 800 °C, showing the great potential of this work for state sensing on the surface of high-temperature components, especially for customized requirements.

Oxidation and Ablation Behavior of Particle-Filled SiCN Precursor Coatings for Thin-Film Sensors

“…Finally, we used the electrical resistance characteristics of thin-film sensors to characterize the performance of ablation process coating. The thin-film coating was applied to the sensitive layer as an antioxidation layer forming a double-layer structure [ 16 ]. Figure 14 a illustrates the optical image of the sensor prior to ablation, displaying a predominantly light yellow surface.…”

Flexible Copper-Based Thermistors Fabricated by Laser Direct Writing for Low-Temperature Sensing

“…Flexible temperature sensors usually are manufactured based on thermocouples, metal-based resistance temperature detectors, and thermistors. − The thermistor-based temperature sensors have the advantages of high sensitivity, cost efficiency, miniaturization, and rapid response time and usually behave with the property of negative temperature coefficient (NTC) of resistance . Traditional thermistors are sintered by transition-metal oxide ceramic materials like Mn-spinel oxide in a thin film, which requires high fabrication temperature. , Meanwhile, a high fabrication temperature prevents the sintered thermistors from deposition on the flexible substrates and leads to high energy consumption and increasing cost.…”

“…It is vitally significant to develop a novel fabrication process of flexible thermistors to overcome those drawbacks. Laser direct writing (LDW), with the advantage of nonmasks, one-step patterning, and high accuracy, is quite suitable for manufacturing flexible electronics facilely and efficiently on a large scale in the room-temperature range. ,− The LDW process has a huge potential for fabricating flexible metal oxide thermistors.…”

All-Three-Dimensionally-Printed AgPd Thick-Film Strain Gauge with a Glass–Ceramic Protective Layer for High-Temperature Applications

“…Real-time monitoring of the surface strain state of aero-engine turbine blades and other structures in high-temperature environments is critical for their ground testing and lifetime prediction. 1,2 In the field of high-temperature strain sensing, the conventional options mainly include discrete strain gauges, berth-type resistance strain gauges, and fiber Bragg gratings. 3−5 The discrete strain gauges are primarily fixed on the surface of the measured structure through installation or tape, which causes creep errors and interferes with the flow field.…”

“…Real-time monitoring of the surface strain state of aero-engine turbine blades and other structures in high-temperature environments is critical for their ground testing and lifetime prediction. , In the field of high-temperature strain sensing, the conventional options mainly include discrete strain gauges, berth-type resistance strain gauges, and fiber Bragg gratings. − The discrete strain gauges are primarily fixed on the surface of the measured structure through installation or tape, which causes creep errors and interferes with the flow field. − Embedding fiber Bragg gratings into metal structures can adversely impact the structural integrity of the components and increase the risk of damage . Therefore, these strain gauges have struggled to meet the demand for in situ strain monitoring of hot-end components.…”