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<p>The oxidation-resistant coating of aeronautic engines must withstand severe thermal fluctuations that can degrade performance over time. Conventional thermal shock and fatigue tests using external heaters suffer from high thermal inertia, complex setups, and poor adaptability at elevated temperatures. To address these challenges, we developed a thermal resistance tester based on ultra-high temperature rapid direct resistance heating. This method enables fast and precise temperature control without the need for external heaters, significantly improving system responsiveness and reliability. The apparatus covers a wide temperature range (500&#xa0;°C to &gt; 3000&#xa0;°C), with temperature accuracy of ± 5&#xa0;°C and weighing precision of ± 0.1&#xa0;mg. It is suitable for evaluating oxidation-resistant coatings and metallic materials with symmetric structures, such as those fabricated via 3D-printed topology optimization. The tester’s performance has been validated through systematic thermal cycling experiments. In addition to coating research, the system shows strong potential in the thermal testing of optical materials and components, particularly in high-power laser and space applications, where material stability under rapid temperature variation is critical.</p>

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A rapid resistance heating apparatus for thermal shock and fatigue testing of oxidation resistant coatings

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年10月13日

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  • Dongyang An,
  • Zhao Liu,
  • Shi Cheng,
  • Jiaye Chen,
  • Xianglin Zhang,
  • Shuangshuang Cheng,
  • Jingmin Dai,
  • Peng Xiao,
  • Zengwu Tang

摘要

The oxidation-resistant coating of aeronautic engines must withstand severe thermal fluctuations that can degrade performance over time. Conventional thermal shock and fatigue tests using external heaters suffer from high thermal inertia, complex setups, and poor adaptability at elevated temperatures. To address these challenges, we developed a thermal resistance tester based on ultra-high temperature rapid direct resistance heating. This method enables fast and precise temperature control without the need for external heaters, significantly improving system responsiveness and reliability. The apparatus covers a wide temperature range (500 °C to > 3000 °C), with temperature accuracy of ± 5 °C and weighing precision of ± 0.1 mg. It is suitable for evaluating oxidation-resistant coatings and metallic materials with symmetric structures, such as those fabricated via 3D-printed topology optimization. The tester’s performance has been validated through systematic thermal cycling experiments. In addition to coating research, the system shows strong potential in the thermal testing of optical materials and components, particularly in high-power laser and space applications, where material stability under rapid temperature variation is critical.