Sensor inserts on spherical surfaces for temperature measurement in wear contacts

Wear and the resulting temperature has a significant influence on the frictional contact behavior of two surfaces in contact. In order to establish accurate wear prediction models, it is essential to measure the temperature at the point of action. This work shows the approach for manufacturing a component-inherent temperature sensor on a ceramic sphere via laser structuring in order to measure friction-induced temperature changes precisely at the point of action during tribologically relevant ball-on-disc tests. Within this paper, different sensor layouts are tested and the sensor fabrication and high temperature contacting via laser direct structuring on ceramics is revealed in detail. A TCR of 2440 +/- 123 ppm/degrees C could be achieved after an annealing process for the layout with the smallest line width. Measurements of the wear resistance of the Al2O3 layer showed, that the sensors life span enables a sliding distance of at least 1,000 mm. During the tribological testing, friction induced temperature changes as well as short-term temperature peaks were measured.