High-Temperature-Sensing Smart Bolt Based on Indium Tin Oxide/In<sub>2</sub>O<sub>3</sub> Thin-Film Thermocouples with Nickel-Based Single-Crystal Superalloy via Screen Printing
In this study, thin-film thermocouples (TFTCs) were combined with a smart bolt to design a smart bolt that can directly test high temperature in service monitoring and parameter calculation for gas turbine structure design. The first-principles calculation was used to analyze the design of the surfa...
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-08-01
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| Series: | Chemosensors |
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| Online Access: | https://www.mdpi.com/2227-9040/10/9/347 |
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| author | Zhongkai Zhang Jiangjiang Liu Rongfu Cai Zhaojun Liu Jiaming Lei Ruolin Sun Ningning Wu Na Zhao Bian Tian Libo Zhao |
| author_facet | Zhongkai Zhang Jiangjiang Liu Rongfu Cai Zhaojun Liu Jiaming Lei Ruolin Sun Ningning Wu Na Zhao Bian Tian Libo Zhao |
| author_sort | Zhongkai Zhang |
| collection | DOAJ |
| description | In this study, thin-film thermocouples (TFTCs) were combined with a smart bolt to design a smart bolt that can directly test high temperature in service monitoring and parameter calculation for gas turbine structure design. The first-principles calculation was used to analyze the design of the surface properties of nickel-based alloys and insulating layers, and finite element analysis was used to optimize dimension parameters by controlling the thermal stress matching of insulating layers and sensitive layers. The effect of the glass powder with different particle sizes on the microstructure of the ITO and In<sub>2</sub>O<sub>3</sub> films was studied via SEM. The preferred particle size of the additive glass powder is 400 nm. The XRD pattern shows the (222) peak has the highest intensity. The intensities of the (222) and (622) peaks increase after the heat treatment. The calibration results show that the average Seebeck coefficient of the TFTCs can reach 64.9 μV/°C at 1100 °C with a maximum voltage of 71.4 mV. The repeatability error of the cycles of the sensor after heat treatment is ±1.05%. The repeatability of the sensor is up to 98.95%. The smart bolts were tested for application in small aero engines. It can be seen that under the impact of 1000 °C, the thermal response of the prepared smart bolt is better than that of the K-type armored thermocouple, and the thermal balance is achieved faster. The intelligent bolt sensor proposed in this work has better engineering application prospects owing to its convenience of installation in harsh environments. |
| first_indexed | 2024-03-10T00:24:39Z |
| format | Article |
| id | doaj.art-4cad4f81d88a494193143d4ca43b50e7 |
| institution | Directory Open Access Journal |
| issn | 2227-9040 |
| language | English |
| last_indexed | 2024-03-10T00:24:39Z |
| publishDate | 2022-08-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Chemosensors |
| spelling | doaj.art-4cad4f81d88a494193143d4ca43b50e72023-11-23T15:35:35ZengMDPI AGChemosensors2227-90402022-08-0110934710.3390/chemosensors10090347High-Temperature-Sensing Smart Bolt Based on Indium Tin Oxide/In<sub>2</sub>O<sub>3</sub> Thin-Film Thermocouples with Nickel-Based Single-Crystal Superalloy via Screen PrintingZhongkai Zhang0Jiangjiang Liu1Rongfu Cai2Zhaojun Liu3Jiaming Lei4Ruolin Sun5Ningning Wu6Na Zhao7Bian Tian8Libo Zhao9State Key Laboratory for Manufacturing Systems Engineering, Institute of Precision Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, ChinaState Key Laboratory for Manufacturing Systems Engineering, Institute of Precision Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, ChinaState Key Laboratory for Manufacturing Systems Engineering, Institute of Precision Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, ChinaState Key Laboratory for Manufacturing Systems Engineering, Institute of Precision Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, ChinaState Key Laboratory for Manufacturing Systems Engineering, Institute of Precision Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, ChinaBeijing Aerospace Technology Research Institute, Beijing 100074, ChinaBeijing Aerospace Technology Research Institute, Beijing 100074, ChinaState Key Laboratory for Manufacturing Systems Engineering, Institute of Precision Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, ChinaState Key Laboratory for Manufacturing Systems Engineering, Institute of Precision Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, ChinaState Key Laboratory for Manufacturing Systems Engineering, Institute of Precision Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, ChinaIn this study, thin-film thermocouples (TFTCs) were combined with a smart bolt to design a smart bolt that can directly test high temperature in service monitoring and parameter calculation for gas turbine structure design. The first-principles calculation was used to analyze the design of the surface properties of nickel-based alloys and insulating layers, and finite element analysis was used to optimize dimension parameters by controlling the thermal stress matching of insulating layers and sensitive layers. The effect of the glass powder with different particle sizes on the microstructure of the ITO and In<sub>2</sub>O<sub>3</sub> films was studied via SEM. The preferred particle size of the additive glass powder is 400 nm. The XRD pattern shows the (222) peak has the highest intensity. The intensities of the (222) and (622) peaks increase after the heat treatment. The calibration results show that the average Seebeck coefficient of the TFTCs can reach 64.9 μV/°C at 1100 °C with a maximum voltage of 71.4 mV. The repeatability error of the cycles of the sensor after heat treatment is ±1.05%. The repeatability of the sensor is up to 98.95%. The smart bolts were tested for application in small aero engines. It can be seen that under the impact of 1000 °C, the thermal response of the prepared smart bolt is better than that of the K-type armored thermocouple, and the thermal balance is achieved faster. The intelligent bolt sensor proposed in this work has better engineering application prospects owing to its convenience of installation in harsh environments.https://www.mdpi.com/2227-9040/10/9/347sensorfilmthermoelectricity |
| spellingShingle | Zhongkai Zhang Jiangjiang Liu Rongfu Cai Zhaojun Liu Jiaming Lei Ruolin Sun Ningning Wu Na Zhao Bian Tian Libo Zhao High-Temperature-Sensing Smart Bolt Based on Indium Tin Oxide/In<sub>2</sub>O<sub>3</sub> Thin-Film Thermocouples with Nickel-Based Single-Crystal Superalloy via Screen Printing Chemosensors sensor film thermoelectricity |
| title | High-Temperature-Sensing Smart Bolt Based on Indium Tin Oxide/In<sub>2</sub>O<sub>3</sub> Thin-Film Thermocouples with Nickel-Based Single-Crystal Superalloy via Screen Printing |
| title_full | High-Temperature-Sensing Smart Bolt Based on Indium Tin Oxide/In<sub>2</sub>O<sub>3</sub> Thin-Film Thermocouples with Nickel-Based Single-Crystal Superalloy via Screen Printing |
| title_fullStr | High-Temperature-Sensing Smart Bolt Based on Indium Tin Oxide/In<sub>2</sub>O<sub>3</sub> Thin-Film Thermocouples with Nickel-Based Single-Crystal Superalloy via Screen Printing |
| title_full_unstemmed | High-Temperature-Sensing Smart Bolt Based on Indium Tin Oxide/In<sub>2</sub>O<sub>3</sub> Thin-Film Thermocouples with Nickel-Based Single-Crystal Superalloy via Screen Printing |
| title_short | High-Temperature-Sensing Smart Bolt Based on Indium Tin Oxide/In<sub>2</sub>O<sub>3</sub> Thin-Film Thermocouples with Nickel-Based Single-Crystal Superalloy via Screen Printing |
| title_sort | high temperature sensing smart bolt based on indium tin oxide in sub 2 sub o sub 3 sub thin film thermocouples with nickel based single crystal superalloy via screen printing |
| topic | sensor film thermoelectricity |
| url | https://www.mdpi.com/2227-9040/10/9/347 |
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