Fabrication and characterization of a streamlined micro hot wire probe to reduce aerodynamic disturbances

The miniaturization of sensing elements in hot-wire anemometry through micro-fabrication techniques enables high temporal and spatial resolution, essential for investigating complex and high-speed flows. However, hot-wire probes remain inherently intrusive, and minimizing disturbances caused by the probe is critical for accurate measurements at small scales. This study focuses on the development of a micro hot-wire ( x μ HW) sensor with reduced disturbances through the implementation of a streamlined geometry. By developing a micro-fabrication process, based among others on silicon’s aspect ratio-dependent etching properties, a new sensor prototype was produced. Experimental characterization in a wall-bounded flow highlights the potential and limitations of this streamlined design for aerodynamic applications. • Developed a streamlined micro-sensor to reduce flow disturbance during measurement. • Demonstrated benefits of micro-sensor shaping in free-stream turbulence conditions. • Used silicon etching techniques to create a 3D aerodynamic micro-probe geometry.