Hybrid Metal–ceramic Fiber Frameworks Based on Designs of Metallic Coatings for High-temperature Resistant Temperature–pressure Sensing

Abstract

Extreme thermal environments demand sensors with two mutually exclusive properties: flexibility (to conform curved surfaces and withstand dynamic stress) and high-temperature tolerance (to avoid degradation above 400 °C). However, existing polymer-based flexible sensors are thermally unstable, and conventional high-temperature sensors of ceramic and metal are inflexible. Herein, we address this challenge with a hybrid metal–ceramic framework of Pt_xAu_1−x coated ZrO₂-Al₂O₃ nanofibers (Pt_xAu_1−x@ZANF), enabling flexible dual-functional temperature–pressure sensing up to 800 °C. Systematic studies on solid-state dewetting, nano-grain melting, and phase stability identified Au-rich Pt_0.15Au_0.85 as optimal: it retains a single face-centered cubic phase and low resistivity (< 1 order of magnitude increase) after 2 h at 800 °C in air, outperforming pure Pt/Au and Pt-rich alloys (prone to phase separation/spheroidization). Laser-patterned electrodes on Pt_0.15Au_0.85@ZANF yield a dual-functional temperature–pressure sensor, which exhibits both high-temperature resistance and flexibility. The sensor exhibited a sensitivity range of 0.019 kPa⁻¹ to 0.054 kPa⁻¹ and demonstrated stability over 360 cycles (≥ 3 h) at 800 °C, far exceeding the maximum operating temperature of other reported temperature–pressure sensors (≤ 300 °C). This framework combines flexibility and high-temperature tolerance, two essential properties for reliable sensing on curved industrial robot joints, chemical plant reactors, and spacecraft surfaces.

Graphical Abstract

Keywords

Flexible high-temperature sensor / Dual-functional sensor / Temperature and pressure sensing / Flexible ceramic fibers / Hybrid fiber materials

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Funding

National Natural Science Foundation of China(52375566)

Ministry of Education of China(SRICSPYF-ZY2025030)

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Donghua University, Shanghai, China

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