Active sensing using ultrasonic guided waves (UGW) is widely investigated for monitoring possible damages in composite structures. Recently, a novel diagnosed film based on a circuit-printed technique with piezoelectric lead zirconate titanate (PZT) transducers has been developed. The diagnostic film is a replacement for the traditional cable connection to PZT sensors and has been shown to significantly reduce the weight of the host structure. In this work, the diagnosed films were embedded into composite structures during manufacturing using a novel edge cut-out method during lay-up, which allowed for edge trimming after curing. In this paper, the effect of fatigue loading on the integrity of PZT transducers is initially investigated. The electro-mechanical impedance (EMI) properties at different fatigue loading cycles were used as the diagnostic measure for the performance of the sensors. At the same time, the behaviours of UGW were investigated at different fatigue loading cycles. It was found that the EMI properties and active sensing behaviours remained stable up to 1 million cycles for the force ranges of 0.5~5 kN and 1~10 kN. Next, the effect of embedding the diagnosed film on the mechanical properties of the host composite structure was investigated. Tensile and compressive tests were conducted and the elastic modulus of composite coupons with and without embedded PZT diagnosed films were compared. The elastic modulus of composite coupons with PZT diagnosed films embedded across the entire coupon reduced by as much as 20% for tensile tests and just over 10% for compressive tests compared to the coupons without embedded sensors. These reductions are considered the worst-case scenario, as in real structures the film would only be embedded in a relatively small area of the structure.

An effective approach for an embedded piezo diagnostic layer into thick composite material is presented. The effectiveness of the approach is assessed in comparison to the surface-mounted layer. The proposed manufacturing alleviates difficulties associated with trimming edges of composites when embedding wires. The Electro-Mechanical Impedance technique is used to access the integrity of the piezoelectric sensors bonding process. Comparisons of ultrasonic guided waves are made between embedded and surface-mounted diagnostic layers and their penetration through and across the thickness of the composites. Temperature influences with the range from −40 °C up to 80 °C on embedded and surface-mounted guided waves are investigated. An investigation is carried out into the relationship between amplitude and time-of-flight with temperature at different excitation frequencies. The temperature has significant but different effects on amplitude and phase-shift of guided waves for the embedded layer compared to the surface-mounted layer. A Laser Doppler Vibrometer is used to identify the blue tack and impact damage. Both embedded and surface-mounted layers are shown to be an effective means of generating detectable wave scatter from damage.

In this paper, the propagation properties of ultrasonic guided waves (UGWs) in different-thickness composites (i.e., 2, 4 and 9 mm) were critically assessed, and their effectiveness for damage detections and localisations under varying temperatures was demonstrated. A diagnostic film with phased-array lead zirconate titanate (PZT) transducers based on the ink-jet printing technique was used in the experiments. Initially, the dispersion curves for these composites were compared. Next, the effects of the composite thickness on the A₀ and S₀ mode amplitudes and the group velocity were investigated by active sensing. Next, the behaviours of UGWs under varying temperatures in different-thickness plates were also investigated. Finally, surface-mounted artificial damage and impact damage were detected and located in different composites.

The bondline integrity of a repair patch to the parent composite laminate is considered the most important factor in the repair design. A smart repair patch is proposed here to allow for real-time ultrasonic guided wave monitoring of repaired composites. A diagnostic film with lead zirconate titanate (PZT) transducers and inkjet-printed wires is embedded into the repair patch using a cut-out method. The electro-mechanical impedance (EMI) method is used to verify the integrity of the embedded PZT transducers. The performance of the smart repair patch is assessed on the external panel with artificial bondline delamination and surface-mounted artificial damage. The damage index correlation coefficient and delay-and-sum (DAS) algorithm are used for damage detection and localization. The results show that the developed repair patch can successfully detect and locate damages.

Superhydrophobic nanocomposite coatings, prepared using adhesive and fillers, offer advantages including ease of fabrication and suitability for large-scale applications, but compared with other types of artificial superhydrophobic surfaces, poor durability still limits these surfaces from practical applications. The utilization of micro/nanoscale particles with both intrinsic hydrophobicity and robust mechanical properties to prepare coatings should significantly contribute to enhanced durability. Herein, rough and hydrophobic particles with micro/nano hierarchical structures were prepared at first, and robust superhydrophobic surfaces were fabricated using the prepared particles and additional nanoparticles. The initially prepared particles formed a rough framework of the coating, while additional nanoparticles provided inevitable nanoscale structures. A series of mechanical tests were carried out to validate the durability, and the surface with 20 wt.% NPs exhibited the best performance, withstanding 30 tape peeling tests, a 2.47 m sandpaper rubbing test (at a pressure of 5 kPa), the impact of 200 g of grit dropped from a height of 20 cm, and a 2 h acidic immersion. These appealing materials may attract attention for self-cleaning, high-speed water impact resistance, anti-icing, and anti-fouling applications in the coatings industry.

This paper describes a study that focuses on assessing the influence of composites with different thicknesses (2 mm, 4 mm, and 9 mm) on embedded ultrasonic guided waves (UGWs) under varying temperatures. The study also demonstrates the effectiveness of these embedded sensors in identifying damage. A novel cut-out method that included an embedded diagnostic layer and phased-array lead zirconate titanate (PZT) transducers, created using the ink-jet printing technique in the manufacturing process was employed. The research then focused on studying the behavior of UGWs under varying temperatures for each composite panel. This analysis aimed to understand how temperature variations affected the propagation of guided waves in thick composites. Finally, artificial damage on the surface and impact damage were introduced, both embedded and surface-mounted PZT transducers were used to detect and locate these damages in different thickness composite panels. The results of damage localization indicated that the embedded PZT transducers were more sensitive than the surface-mounted transducers in locating the damage in thick composites.