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<p>The progress of Structural Health Monitoring (SHM) requires the development of low-cost, scalable, and environmentally friendly sensors for reliable damage detection. This research details the fabrication, characterization, and validation of two novel sensor types for crack detection: a lead-free piezoelectric composite and a flexible piezoresistive film. A piezoelectric sensor was fabricated using a 70% Barium Titanate (BT) and 30% epoxy matrix. The sensor’s performance was evaluated through a suite of mechanical tests. Dynamic characterization showed a clear response to impacts, generating signals up to 7.2 µV, and to vibrations, with a response frequency identical to the excitation source. Crucially, during fatigue tests conducted according to ASTM E647, the sensor generated a robust and unambiguous alarm signal of 66 µV upon catastrophic fracture. It was also demonstrated that sensor geometry can be optimized for early crack detection, with a narrower sensor detecting crack initiation at 34.8% of the specimen’s fatigue life, compared to 46.7% for a standard-width sensor. Concurrently, a sensor based on the piezoresistive material Velostat was tested under tensile loading. The results showed a direct and highly consistent correlation between crack initiation and a 15% increase in the sensor’s electrical resistance from its initial state. This work successfully validates these innovative and accessible methods, establishing a clear fabrication methodology and providing quantitative performance data that contributes to the development of next-generation SHM systems.</p>

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A novel approach to crack detection using lead-free piezoelectric composites and piezoresistive films for structural health monitoring

  • 期刊论文

  • 发表日期：

    2026年6月3日

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  • Vicente Araya,
  • Carlos Lanziotti,
  • Cristián Vicuña,
  • Angelo Oñate,
  • Víctor Tuninetti

摘要

The progress of Structural Health Monitoring (SHM) requires the development of low-cost, scalable, and environmentally friendly sensors for reliable damage detection. This research details the fabrication, characterization, and validation of two novel sensor types for crack detection: a lead-free piezoelectric composite and a flexible piezoresistive film. A piezoelectric sensor was fabricated using a 70% Barium Titanate (BT) and 30% epoxy matrix. The sensor’s performance was evaluated through a suite of mechanical tests. Dynamic characterization showed a clear response to impacts, generating signals up to 7.2 µV, and to vibrations, with a response frequency identical to the excitation source. Crucially, during fatigue tests conducted according to ASTM E647, the sensor generated a robust and unambiguous alarm signal of 66 µV upon catastrophic fracture. It was also demonstrated that sensor geometry can be optimized for early crack detection, with a narrower sensor detecting crack initiation at 34.8% of the specimen’s fatigue life, compared to 46.7% for a standard-width sensor. Concurrently, a sensor based on the piezoresistive material Velostat was tested under tensile loading. The results showed a direct and highly consistent correlation between crack initiation and a 15% increase in the sensor’s electrical resistance from its initial state. This work successfully validates these innovative and accessible methods, establishing a clear fabrication methodology and providing quantitative performance data that contributes to the development of next-generation SHM systems.