Study of the effect of temperature, thickness and roughness on the dynamic characteristics of fast-response polymer-ceramic pressure-sensitive paint

Purpose This study aims to systematically analyze pressure sensitivity and dynamic characteristics of polymer-ceramic pressure-sensitive paint (PC-PSP) at different temperatures, coating thicknesses and surface roughness levels using a standing wave tube calibration system, addressing measurement errors in wind tunnel experiments. Design/methodology/approach Multiple PC-PSP samples with varying thicknesses and roughness levels were prepared and tested under controlled temperature conditions. Surface roughness was adjusted using sandpaper grinding, while a temperature control unit maintained specific thermal conditions. The experimental setup allowed simultaneous measurement of static pressure sensitivity and dynamic response characteristics. Findings Results show PC-PSP pressure sensitivity has a nonlinear relationship with coating thickness − initially increasing, peaking at optimal moderate thickness and decreasing. Increased surface roughness enhanced sensitivity, likely due to augmented oxygen quenching effects. Cut-off frequency exhibited similar nonlinear behavior with thickness, indicating an optimal thickness range exists for maximizing dynamic response, while surface roughness had minimal impact on dynamic performance. Research limitations/implications Engineers can optimize PC-PSP performance by maintaining coating thickness within 60–80 μm for optimal sensitivity and dynamic response. Strategically increasing surface roughness improves pressure sensitivity without significantly affecting dynamic response. Higher temperatures (30°C–50°C) enhance both sensitivity and cut-off frequency, providing a practical method for improved measurement performance in aerospace testing facilities. Originality/value To the best of the authors’ knowledge, this study provides the first comprehensive analysis of temperature, thickness and roughness effects on PC-PSP performance using a CMOS-based imaging system. The identification of nonlinear relationships and optimal parameter ranges represents significant advancement in pressure-sensitive coating optimization for high-precision aerospace applications.