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prone to fatigue fractures. Real-time and accurate monitoring of blade surface stress and strain is critical to ensure safe operation. In this study, thin-film strain gauges (TFSGs) that can be used in high-temperature environments above 1000 \u00b0C were designed and fabricated using a PtRh6 thin film as the sensitive material. The hysteresis effect of the stress transfer upon establishing a thermo-mechanical coupling finite element model of the Inconel718 high-temperature nickel-based alloy equal-strength beam PtRh6 TFSGs was analyzed and the optimal combination of thin-film thickness and longitudinal grid length of wire-grid TFSGs was determined. In order to solve the problem of high-temperature insulation, the insulating properties of a single-layer Al2O3 insulating film, a single-layer ZrO2 insulating film, a double-layer Al2O3\/ZrO2 composite insulating film, and a four-layer Al2O3\/ZrO2\/Al2O3\/ZrO2 composite insulating film at high temperature were compared and studied using scanning electron microscopy to analyze the microscopic morphology and composition of the four insulating film structures. The results showed that the four-layer Al2O3\/ZrO2\/Al2O3\/ZrO2 composite insulating film had the best insulating properties at high temperatures. On this basis, an Al2O3\/ZrO2\/Al2O3\/ZrO2 composite insulating film, PtRh6 sensitive layer, and Al2O3 protective film were sequentially deposited on a high-temperature nickel-based alloy equal-strength beam using DC pulsed magnetron sputtering technology to obtain an Inconel718 high-temperature nickel-based alloy equal-strength beam PtRh6 TFSG. Its gauge factor (GF) and temperature coefficient of resistance (TCR) were calibrated, and the results showed that the sensor could be used in harsh environments of 1000 \u00b0C. The above results provide new ideas for measuring stress and strain in aerospace under high-temperature and high-pressure environments.<\/jats:p>","DOI":"10.3390\/s22197595","type":"journal-article","created":{"date-parts":[[2022,10,10]],"date-time":"2022-10-10T05:12:21Z","timestamp":1665378741000},"page":"7595","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":21,"title":["Development of High-Temperature Wire-Grid Thin Film Strain Gauges"],"prefix":"10.3390","volume":"22","author":[{"ORCID":"https:\/\/orcid.org\/0000-0002-9066-5000","authenticated-orcid":false,"given":"Yunxian","family":"Cui","sequence":"first","affiliation":[{"name":"School of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Xin","family":"Li","sequence":"additional","affiliation":[{"name":"School of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Tenglun","family":"Zhang","sequence":"additional","affiliation":[{"name":"Nanjing Kangni Mechanical & Electrical Co., Ltd., Nanjing 210013, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Wanyu","family":"Ding","sequence":"additional","affiliation":[{"name":"School of Materials Science and Engineering, Dalian Jiaotong University, Dalian 116028, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Junwei","family":"Yin","sequence":"additional","affiliation":[{"name":"School of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, China"}],"role":[{"role":"author","vocabulary":"crossref"}]}],"member":"1968","published-online":{"date-parts":[[2022,10,7]]},"reference":[{"key":"ref_1","first-page":"358","article-title":"Performance study of technology of combustion inside turbine using in fanjet","volume":"28","author":"Li","year":"2010","journal-title":"Acta Aerodyn. 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