Dynamic Calibration of a Thin-Film Heat-Flux Sensor in Time and Frequency Domains

This paper mainly studies the model design of a thin-film heat-flux sensor (TFHFS), and focuses on the comparison of three dynamic calibration methods. The primary motivation for studying this came from the urgent need for heat-flux dynamic measurements in extreme environments, and the one-sidedness of the dynamic performance evaluation of the corresponding TFHFS. The dynamic theoretical model of the TFHFS was originally established on the principle of a temperature gradient on the basis of a thermal radiation boundary. Then, a novel TFHFS sensor was developed, which can be used at temperatures above 880 °C and has a high sensitivity of 2.0 × 10^-5 mV/(W/m²). It can function stably for long durations under a heat-flux density of 3 MW/m². The steady-state, transient, and frequency calibration of a TFHFS were compared to comprehensively analyze the dynamic characteristics of the TFHFS. The steady-state response time measured by the step excitation method was found to be 0.978 s. The QR decomposition method was applied to the steady-state response experimental model construction, and the fitting degree of a second-order transfer function model obtained was 98.61%. Secondly, the transient response time of the TFHFS was 0.31 ms based on the pulse-excitation method. The transient relationship between the surface temperature and the heat flux, and the pulse-width dependence of the TFHFS transient response time were established. Surprisingly, the response frequency of the TFHFS, about 3000 Hz, was efficiently tested using the frequency response function (FRF), which benefitted from the harmonic characteristics of a periodic square-wave excitation signal. Finally, a comprehensive evaluation of the dynamic performance of the TFHFS was realized.