Metal structures embedded with piezoelectric PVDF sensors using ultrasonic additive manufacturing

Ramanathan, Arun Kumar; Gingerich, M. Bryant; Headings, Leon M.; Dapino, Marcelo J.

doi:10.1016/j.mfglet.2021.08.001

Cited by 15 publications

(18 citation statements)

References 21 publications

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“…In the above sections, we found that the oxygen within PEEK and grafted COOH would react with the surficial aluminum of 6061 to form interfacial Al–O covalency that allowed the direct bonds between 6061 and PEEK or PEEK-PP. In practice, some thermoplastics such as PPS, PVC, acrylonitrile-butadiene-styrene (ABS), and polyvinylidene fluoride (PVDF) containing no oxygen could be directly bonded to metals. It is necessary to point out that those thermoplastics contain high-electronegativity elements (sulfur, chlorine, nitrogen, and fluorine) like oxygen, which might form covalent bonds with surficial metallic elements.…”

Section: Resultsmentioning

confidence: 99%

A Conceptual Strategy toward High-Reliability Metal–Thermoplastic Hybrid Structures Based on a Covalent-Bonding Mechanism

Xie

et al. 2022

ACS Appl. Mater. Interfaces

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Metal−thermoplastic hybrid structures have proven their effectiveness to achieve lightweight design concepts in both primary and secondary structural components of advanced aircraft. However, the drastic differences in physical and chemical properties between metal and thermoplastic make it challenging to fabricate high-reliability hybrid structures. Here, a simple and universal strategy to obtain strong hybrid structures thermoplastics is reported by regulating the bonding behavior at metal/ thermoplastic interfaces. To achieve such, we first researched and uncovered the bonding mechanism at metal/thermoplastic interfaces by experimental methods and density functional theory (DFT) calculations. The results suggest that the interfacial covalency, which is formed due to the interfacial reaction between high-electronegativity elements of thermoplastics and metallic elements at metal surfaces, dominates the interfacial bonding interaction of metal−thermoplastic hybrid structures. The differences in electronegativity and atomic size between bonding atoms influence the covalent-bond strength and finally control the interfacial reliability of hybrid structures. Based on our covalent-bonding mechanism, the carboxyl functional group (COOH) is specifically grafted on polyetheretherketone (PEEK) by plasma polymerization to increase the density and strength of interfacial covalency and thus fabricate high-reliability hybrid structures between PEEK and A6061-T6 aluminum alloy. Current work provides an in-depth understanding of the bonding mechanism at metal−thermoplastics interfaces, which opens a fascinating direction toward highreliability metal−thermoplastic hybrid structures.

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Section: Resultsmentioning

confidence: 99%

A Conceptual Strategy toward High-Reliability Metal–Thermoplastic Hybrid Structures Based on a Covalent-Bonding Mechanism

Xie

et al. 2022

ACS Appl. Mater. Interfaces

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“…Currently, applications in metal components [94,[105][106][107][108][109] use sensitively ceramic and polymeric piezoelectric sensors, more specifically PZT sensors [105] and Piezoelectric Polyvinylidene Fluoride (PVDF) sensors [109]. Traditional manufacturing approaches to incorporating active materials, such as piezoelectric materials, into metals can be problematic due to their high temperatures during production or the long curing times of the adhesives used to connect the sensor to the metal.…”

Section: Applications For Metal Componentsmentioning

confidence: 99%

“…Traditional manufacturing approaches to incorporating active materials, such as piezoelectric materials, into metals can be problematic due to their high temperatures during production or the long curing times of the adhesives used to connect the sensor to the metal. To bridge the challenges that technological processes present, the scientific community has carried out a set of developments, among them, their focus on the development of a process of "stop and go", which consists of taking a break in the manufacturing process of a given component to allow the inclusion of PSs [105], or the inclusion of sensors through the joining of metal components in the solid-state, i.e., by ultrasonic additive manufacturing [109].…”

Section: Applications For Metal Componentsmentioning

confidence: 99%

“…The studies carried out so far proved the feasibility of manufacturing smart components with ESs. In addition, they can evaluate the component performance, leading to the possibility of manufacturing smart components that can have an impact in industries, such as the energy, aerospace, automotive and biomedical industries, or for applications such as air/fuel premix, pressure pipes and turbine blades [94,105,109].…”

Section: Applications For Metal Componentsmentioning

confidence: 99%

“…These technologies are the Shape Deposition Manufacturing (Figure 11 a)), the Electron Beam Melting (Figure 11 b)), the Magnetron sputtering and Electroplating (Figure 11 c)), and the Ultrasonic Additive Manufacturing (Figure 11 d)). [76][77][78][79][80][81][82][83][84][85]105,106,108,109,[122][123][124][125][126][130][131][132][133].…”

Section: For Metal Componentsmentioning

confidence: 99%

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Embedded Sensors for Structural Health Monitoring: Methodologies and Applications Review

Ferreira¹,

Machado²,

Carvalho³

et al. 2022

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Sensing Technology (ST) plays a key role in Structural Health Monitoring (SHM) systems. ST focuses on developing sensors, sensory systems or smart materials that monitor a wide variety of materials properties aiming to create smart structures and smart materials, using Embedded Sensors (ESs), and allowing continuous and permanent measurements of the structural integrity. The integration of ESs is limited to the processing technology to embed the sensor due to its high-temperature sensitivity and the possibility of damage during its insertion into the structure. In addition, the technological process selection is dependent on the base material composition, either metallic or composite parts. The selection of smart sensors or the technology underlying them is fundamental to the monitoring mode. This paper presents a critical review of the fundaments and applications of sensing technologies for SHM employing ESs, focusing on the actual developments and innovation of these, as well as analysing the challenges that these technologies present, to build a path that allows a connected world through distributed measurement systems.

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In situ embedment of type K sheathed thermocouples with directed energy deposition

Nuñez

Sabharwall

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Metal structures embedded with piezoelectric PVDF sensors using ultrasonic additive manufacturing

Cited by 15 publications

References 21 publications

A Conceptual Strategy toward High-Reliability Metal–Thermoplastic Hybrid Structures Based on a Covalent-Bonding Mechanism

A Conceptual Strategy toward High-Reliability Metal–Thermoplastic Hybrid Structures Based on a Covalent-Bonding Mechanism

Embedded Sensors for Structural Health Monitoring: Methodologies and Applications Review

In situ embedment of type K sheathed thermocouples with directed energy deposition

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