Application of the Composite Electrical Insulation Layer with a Self-Healing Function Similar to Pine Trees in K-Type Coaxial Thermocouples

Aerospace engines and hypersonic vehicles, among other high-temperature components, often operate in environments characterized by temperatures exceeding 1000 °C and high-speed airflow impacts, resulting in severe thermal erosion conditions. Coaxial thermocouples (CTs), with their unique self-eroding characteristic, are particularly well suited for use in such extreme environments. However, fabricating high-temperature electrical insulation layers for coaxial thermocouples remains challenging. Inspired by the self-healing mechanism of pine trees, we designed a composite electrical insulation layer with a similar self-healing function. This composite layer exhibits excellent high-temperature insulation properties (insulation resistance of 14.5 kΩ at 1200 °C). Applied as the insulation layer in K-type coaxial thermocouples via dip-coating, the thermocouples were tested for temperature and heat flux. Temperature tests showed an accuracy of 1.72% in the range of 200–1200 °C, a drift rate better than 0.474%/h at 1200 °C, and hysteresis better than 0.246%. The temperature response time was 1.08 ms. Heat flux tests demonstrated a measurable range of 0–41.32 MW/m2 with an accuracy better than 6.511% and a heat flux response time of 7.6 ms. In simulated extreme environments, the K-type coaxial thermocouple withstood 70 s of 900 °C flame impact and 50 cycles of high-power laser thermal shock.