Commercially available photopolymer resins can be combined with lead zirconate titanate (PZT) micrometer size piezoelectric particles to form 3D-printable suspensions that solidify under UV light. This in turn makes it possible to realize various non-standard sensor geometries which might bring benefits, such as increased piezoelectric output in specific conditions and less interference with incoming waves due to better acoustical adaptation compared to solid PZT ceramics. However, it is unclear whether piezoelectric composite materials are suitable for guided ultrasonic wave (GUW) detection, which is crucial for structural health monitoring (SHM) in different applications. In this study, thin piezoelectric composite sensors are tape casted, solidified under UV light, covered with electrodes, polarized in a high electric field and adhesively bonded onto an isotropic aluminum waveguide. This approach helps to demonstrate the capabilities of tape casting’s freedom to manufacture geometrically differently shaped, thin piezoelectric composite sensors for GUW detection. In an experimental study, thin two-dimensional piezoelectric composite sensors demonstrate successful detection of GUW for frequency-thickness products of up to 0.5 MHz mm. An analytical calculation of the maximum and minimum amplitudes for the ratio of the wavelength and the sensor length in wave propagation direction shows good agreement with the sensor-recorded signals. The output of the piezoelectric composite sensors and occurring reflections as measure for wave interactions are compared to commercial piezoelectric discs to evaluate their performance.

Fiber metal laminates (FMLs) are of high interest for lightweight structures as they combine the advantageous material properties of metals and fiber-reinforced polymers (FRPs). However, low-velocity impacts can lead to complex internal damage. Therefore, structural health monitoring with guided ultrasonic waves (GUWs) is a methodology to identify such damage. Numerical simulations form the basis for corresponding investigations, but experimental validation of dispersion diagrams over a wide frequency range is hardly found in the literature. In this work the dispersive relation of GUWs is experimentally determined for an FML made of carbon FRP and steel. For this purpose, multi-frequency excitation signals are used to generate GUWs and the resulting wave field is measured via laser scanning vibrometry. The data are processed by means of a non-uniform discrete 2d Fourier transform and analyzed in the frequency-wavenumber domain. The experimental data are in excellent agreement with data from a numerical solution of the analytical framework. In conclusion, this work presents a highly automatable method to experimentally determine dispersion diagrams of GUWs in FML over large frequency ranges with high accuracy.

Structural health monitoring of lightweight constructions made of composite materials can be performed using guided ultrasonic waves. If modern fiber metal laminates are used, this requires integrated sensors that can record the inner displacement oscillations caused by the propagating guided ultrasonic waves. Therefore, we developed a robust MEMS vibrometer that can be integrated while maintaining the structural and functional compliance of the laminate. This vibrometer is directly sensitive to the high-frequency displacements from structure-borne ultrasound when excited in a frequency range between its first and second eigenfrequency. The vibrometer is mostly realized by processes earlier developed for a pressure sensor but with additional femtosecond laser ablation and encapsulation. The piezoresistive transducer, made from silicon, is encapsulated between top and bottom glass lids. The eigenfrequencies are experimentally determined using an optical micro vibrometer setup. The MEMS vibrometer functionality and usability for structural health monitoring are demonstrated on a customized test rig by recording application-relevant guided ultrasonic wave packages with a central frequency of 100 kHz at a distance of 0.2 m from the exciting ultrasound transducer.

Increasing the service-life of engineering structures such as aeroplanes is a major issue in order to enhance their cost-effectiveness and to reduce the carbon footprint. One possibility to achieve this goal is to determine the current structural health state and to derive respective measures in order to increase the structure’s technical reliability. For doing so, a structural health monitoring system consisting of both an actuator and a sensor network may be applied. Whereas the actuator induces a wave field of guided ultrasonic waves, the measuring data of the sensors allows to determine the health state of the respective structure. However, both actuators and sensors in most cases distort these wave fields. This distortion may lead to false-detection of damage: both the number and severity of damage may be over- or underestimated. The former leads to an unnecessary high effort for retrofitting the structure, whereas the latter reduces the structure’s technical reliability. Several measures exist in order to avoid such false-detections. In the present contribution, focus is set on reducing the distortion of the wave field which is caused by an embedded sensor. The reduced distortion of the wave field is achieved by an acoustic impedance matching with a functionally graded material which is based on a mechanical model. The approach additionally results in amplified measuring signals of the sensor. The applicability of the proposed approach is shown by means of a numerical study.

Structural health monitoring systems for composite laminates using guided ultrasonic waves become more versatile with the structural integration of sensors. However, the data generated within these sensors have to be transmitted from the laminate to the outside, where polyimide-based printed circuit boards play a major role. This study investigates, to what extent integrated polyimide inlays with applied sensor bodies influence the guided ultrasonic wave propagation in glass fiber-reinforced polymer specimens. For reasons of resource efficiency, narrow specimens are used. Numerical simulations of a damping-free specimen indicate reflections of the $S_0$-mode at the integrated inlay. This is validated experimentally with an air-coupled ultrasonic technique and a 3D laser Doppler vibrometry measurement. The experimental data are evaluated with a method including temporal and spatial continuous wavelet transformations to clearly identify periodically occurring wave packages as edge reflections and distinguish them from possible inlay reflections. However, even when separating in-plane and out-of-plane movements using the 3D measurement, no reflections at the inlays are detected. This leads to the conclusion that polyimide inlays are well suited as substrates for printed circuit boards integrated into fiber-reinforced polymer structures for structural health monitoring, since they do not significantly influence the wave propagation.

Commercially available photopolymer resin is combined with Lead Zirconate Titanate (PZT) micrometer size piezoelectric particles to form 3D printable suspensions that solidify under UV light. This in turn allows achieving various non-standard sensor geometries that might bring benefits, such as increased piezoelectric output in specific conditions. However, it is unclear whether piezoelectric composite materials are suitable for Guided Ultrasonic Wave (GUW) detection, which is crucial for Structural Health Monitoring (SHM) in different applications. In this study, thin piezoelectric composite sensors are tape casted, solidified under UV light, covered with electrodes, polarized in a high electric field and adhesively bonded onto a wave guide. This approach helps to understand the capabilities of thin piezoelectric composite sensors for GUW detection. In an experimental study, thin 2-dimensional rectangular, circular and annulus segment shaped piezoelectric composite sensors with an effective surface area smaller than 400 $\mathrm{m}$$\mathrm{m}$² applied to an aluminum plate with a thickness of 2 $\mathrm{m}$$\mathrm{m}$ demonstrate successful detection of GUW up to 250 $\mathrm{k}$$\mathrm{Hz}$. An analytical calculation of the maximum and minimum amplitude for the ratio of the wavelength and the sensor length in wave propagation direction shows good agreement with the sensor-recorded amplitude. The output of the piezoelectric composite sensors is compared to commercial piezoelectric discs to evaluate their performance.