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Laser Cladding of Embedded Sensors for Thermal Barrier Coating Applications

Materials Synthesis and Processing (IEK-1), Institute of Energy and Climate Research, Forschungszentrum Jülich GmbH, 52425 Jülich, Germany
China Center for Information Industry Development (CCID), Beijing 100048, China
Author to whom correspondence should be addressed.
Coatings 2018, 8(5), 176;
Received: 12 March 2018 / Revised: 20 April 2018 / Accepted: 25 April 2018 / Published: 4 May 2018
(This article belongs to the Special Issue Thermal Barrier Coatings)
PDF [5281 KB, uploaded 7 May 2018]


The accurate real-time monitoring of surface or internal temperatures of thermal barrier coatings (TBCs) in hostile environments presents significant benefits to the efficient and safe operation of gas turbines. A new method for fabricating high-temperature K-type thermocouple sensors on gas turbine engines using coaxial laser cladding technology has been developed. The deposition of the thermocouple sensors was optimized to provide minimal intrusive features to the TBC, which is beneficial for the operational reliability of the protective coatings. Notably, this avoids a melt pool on the TBC surface. Sensors were deposited onto standard yttria-stabilized zirconia (7–8 wt % YSZ) coated substrates; subsequently, they were embedded with second YSZ layers by the Atmospheric Plasma Spray (APS) process. Morphology of cladded thermocouples before and after embedding was optimized in terms of topography and internal homogeneity, respectively. The dimensions of the cladded thermocouple were in the order of 200 microns in thickness and width. The thermal and electrical response of the cladded thermocouple was tested before and after embedding in temperatures ranging from ambient to approximately 450 °C in a furnace. Seebeck coefficients of bared and embedded thermocouples were also calculated correspondingly, and the results were compared to that of a commercial standard K-type thermocouple, which demonstrates that laser cladding is a prospective technology for manufacturing microsensors on the surface of or even embedded into functional coatings. View Full-Text
Keywords: laser cladding; thermocouple sensor; laser cladded sensors; Seebeck coefficient; minimal heat affected zone (HAZ); thermal barrier coatings (TBCs) laser cladding; thermocouple sensor; laser cladded sensors; Seebeck coefficient; minimal heat affected zone (HAZ); thermal barrier coatings (TBCs)

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Zhang, Y.; Mack, D.E.; Mauer, G.; Vaßen, R. Laser Cladding of Embedded Sensors for Thermal Barrier Coating Applications. Coatings 2018, 8, 176.

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