We developed a simple method to prepare hybrid copper-silver conductive tracks under flash light sintering. The developed metal nanoparticle-based ink is convenient because its preparation process is free of any tedious washing steps. The inks were composed of commercially available copper nanoparticles which were mixed with formic acid, silver nitrate, and diethylene glycol. The role of formic acid is to remove the native copper oxide layer on the surface of the copper nanoparticles. In this way, it facilitates the formation of a silver outer shell on the surface of the copper nanoparticles through a galvanic replacement. In the presence of formic acid, the copper nanoparticles formed copper formate, which was present in the unsintered tracks. However, under illumination by a xenon flash light, the copper formate was then converted to copper. Moreover, the resistance of the copper-only films increased by 6 orders of magnitude when oxidized at high temperatures (∼220 °C). However, addition of silver nitrate to the inks suppressed the oxidation of the hybrid copper-silver films, and the resistance changes in these inks at high temperatures were greatly reduced. In addition, the hybrid inks proved to be advantageous for use in electrical circuits as they demonstrated a stable electrical conductivity after exposure to ambient air at 180 °C.
Sensors provide an interface between mechanical systems and the physical world. With the move towards Industry 4.0 and cyber-physical systems, demands for cost-effective sensors are rapidly increasing. Conventional sensors used for monitoring manufacturing processes are often bulky and need complex processes. In this study, a novel high-sensitive nanocomposite-based sensor is developed for measuring strain. The developed sensor is comprised of polyvinylidene fluoride (PVDF) as a piezoelectric polymer matrix, and embedded carbon nanotube (CNT) nanoparticles creating a conductive network. Exhibiting both piezoelectric and piezoresistive properties, the developed sensors are capable of strain measurement over a wide frequency band, including static and dynamic measurements. The piezoresistive and piezoelectric properties are fused to improve the overall sensitivity and frequency bandwidth of the sensor. To simulate the sensor, a 3D random walk model and a 2D finite element (FE) model are used to predict the electrical resistivity and the piezoelectric characteristics of the sensor, respectively. The developed models are verified with the experimental results. The developed nanocomposite sensors were employed for strain measurement of a cantilever beam under static load, impulse excitation, free and forced vibrations, collecting both piezoelectric and piezoresistive properties measurements. The obtained signals were fused and compared with those of a reference sensor. The results show that the sensor is capable of strain measurement in the range of 0–10 kHz, indicating its effectiveness at measuring both static and high frequency signals which is an important feature of the sensor.
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