Abstract
In the digitalization of production, temperature determination is playing an increasingly important role. Thermal spraying and magnetron sputtering were combined for the development of Ni/Ni-20Cr thin film thermocouples for plastic flat film extrusion processes. On the thermally sprayed insulation layer, AlN and BCN thin films were deposited and analyzed regarding their structural properties and the interaction between the plastic melt and the surfaces using Ball-on-Disc experiments and High-Pressure Capillary Rheometer. A modular tool, containing the deposited Ni/Ni-20Cr thin film thermocouple, was developed and analyzed in a real flat film extrusion process. When calibrating the thin film thermocouple, an accurate temperature determination of the flowing melt was achieved. Industrial type K sensors were used as reference. In addition, PP foils were produced without affecting the surface quality by using thin film thermocouples.
Highlights
Self-learning machines play a crucial role in today’s and future production
Thereafter, the Ni/Ni-Cr thin film thermocouple was deposited on the ceramic inserts using a steel masking system reported in [22] to synthesize the individual Ni and Ni-20Cr conducting paths
CrAlN, respectively, films and that the friction coefficient depends on the temperature, and the adhesion behavior is related to Polycarbonate counter balls [31]
Summary
Self-learning machines play a crucial role in today’s and future production. In the 4th Generation. Self-learning machines are still far from being implemented in many industries [1] Data required for these prediction tools can only be generated if the machines are equipped with corresponding sensors, such as temperature-, wear-, distance-, or pressure-sensors, that work exactly. The determination of the temperature, in particular, plays an important role For this purpose, especially thin film thermocouples are suitable, since they reveal a lower mass and a faster reaction time in contrast to bulk thermocouples [2]. Thermal sprayed barrier coatings, such as ZrO2 and Al2 O3 , are suitable for thermal insulation applications since they reveal pores and a higher thickness compared to sputtered coatings These coatings were applied by means of atmospheric plasma spraying and serve as substrate for the thin film thermocouples [19,20]. The application of the Ni/Ni-20Cr thin film thermocouple is proved in a real operation test und compared to a reference bulk thermocouple
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