Hybrid Growth of Clad Crystalline Sapphire Fibers for Ultra-High-Temperature (>1500 °C) Fiber Optic Sensors

Ultra-high-temperature (>1500 °C) sensors play vital roles in ensuring operational excellence in variety of energy-related applications, such as power plant boilers and gas turbine engines. Crystalline sapphire fibers have enormous potential to replace conventional expensive precious metal (e.g., Pt/Rh)-based high-temperature (>1500 °C) sensors by offering higher environmental robustness and distributed sensing capabilities. However, a lack of proper cladding substantially compromises the performance of the sensor. To overcome this fundamental limitation, we develop a hybrid growing method to fabricate low-loss clad crystalline sapphire fibers. We grow a higher-refractive-index doped crystalline sapphire fiber core using the laser-heated pedestal growth (LHPG) method and lower-refractive-index undoped crystalline sapphire fiber cladding using the liquid-phase epitaxy (LPE) method. Furthermore, due to the existence of this cladding layer, a single mode of operation can be achieved at a core diameter size of 30 μm. The experimental results confirm that the grown clad crystalline sapphire fiber can survive in extremely high-temperature (>1500 °C) harsh environments due to the matched coefficient of thermal expansion (CTE) between the fiber core and the cladding. The numerical results also indicate a temperature sensing accuracy of 3.5 °C. This opens the door for developing point and distributed fiber sensor networks capable of enduring extremely harsh environments at extremely high temperatures.