A laser-induced wide-range thin-film temperature sensor without additional anti-oxidative encapsulations

Extreme environments challenge the structural health monitoring of advanced equipment. In-situ dynamic tracking temperature is of particular value due to its enormous impact on material properties. However, the realization of such integrated temperature sensors typically requires complicated layer-by-layer molding and sintering processes including additional thermal barrier coatings. Herein, we report a laser-induced in-situ conductive passivation strategy for the fabrication of a thin-film based wide-range temperature sensor. The instantaneous thermal effect of laser irradiation creates crystalline conductive traces in response to temperature variations. Synchronously, it also allows the formation of an amorphous antioxidative layer without necessitating extra protective coatings. Such configuration enables precise real-time sensing across -50 ◦C to 950 ◦C following the Steinhart-Hart equation. It also exhibits durable performance with only 1.2% drift over 20 hours during long-term high-temperature, instant thermal shock, frequent wearing, and severe vibration. This in-situ, facile laser manufacturing strategy holds great promise in structural health monitoring and fault diagnosis for advanced equipment working in extreme environments.