High-temperature piezoelectric film ultrasonic transducers by a sol-gel spray technique and their application to process monitoring of polymer injection molding

Kobayashi, Makiko; Ono, Yuu; Jen, C. K.; Cheng, Chin‐Chi

doi:10.1109/jsen.2005.856119

Cited by 34 publications

(22 citation statements)

References 16 publications

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“…There are several advantages to this technique, including, but not limited to, a transducer that does not require a bonding medium, repeatable measurements at a constant position of the transducer, structural health monitoring of complex geometry systems, and high-temperature monitoring capabilities. Selected works of Kobayashi that deal with the concept of the composite spray-on transducer are given in Kobayashi and Yen (2004), Kobayashi et al ( , 2006Kobayashi et al ( , 2007, and Barrow et al (1995). The spray-on process was a new deposition technique for thick film deposition of sol-gel ceramics such as the ones characterized by Barrow et al (1995Barrow et al ( , 1997.…”

Section: Recent Developmentsmentioning

confidence: 99%

Effect of sintering temperature on adhesion of spray-on piezoelectric transducers

Sinding¹,

Orr²,

Breon³

et al. 2016

J. Sens. Sens. Syst.

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Abstract. Conventionally sol-gel spray-on transducers require a high-temperature (> 700 • C) sintering process; however, this process can affect the microstructure of the substrate material. For mechanical elbows and valves utilized for fluid transport in the energy sector, the components are designed to have a specific microstructure, and deviations from these specifications can create weak points in the system. For this reason it is important to investigate how the temperature of the deposition process affects the substrate. This paper investigates the effect of high-temperature and low-temperature (< 150 • C) processing conditions on the surface composition of the substrate. Furthermore, the resultant transducers from high-and low-temperature fabrication processes are compared to determine if a low-temperature processing method is feasible. For these studies a sol-gel spray-on process is employed to deposit piezoelectric ceramics onto a stainless-steel 316L substrate. Energy-dispersive X-ray spectroscopy is utilized to determine the composition of the substrate surface before and after transducer deposition. Results indicate that the high-temperature processing conditions may alter the surface composition of the metal due to a diffusion of the metal into the ceramic, which results in a metal surface that is bonded to the ceramic. Furthermore, it is shown that low-temperature processing of spray-on transducers is a viable method for transducer fabrication where the resultant transducers meet the industry minimum requirement of 30 dB signalto-noise ratio. In parallel simulation calculations, finite-element method (FEM) studies were performed to model the adhesive strength of the low-temperature processed transducer to the substrate surface. Comparisons between the simulations and experiments suggest that the bond strength is much greater than the commercial gel bonds and closer to hardened epoxy glue bonds. These results indicate that spray-on transducers fabricated under lowtemperature processing conditions are a viable solution for leave-in-place monitoring of structures.

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Section: Recent Developmentsmentioning

confidence: 99%

Effect of sintering temperature on adhesion of spray-on piezoelectric transducers

Sinding¹,

Orr²,

Breon³

et al. 2016

J. Sens. Sens. Syst.

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show abstract

“…Sol-gel composite ultrasonic transducers have been investigated for the industrial NDT applications [9,10,11,12,13,14,15,16]. Sol-gel composites consist of ferroelectric powders and a dielectric sol-gel solution.…”

Section: Introductionmentioning

confidence: 99%

“…If sol-gel composite films are directly fabricated on the test object, an acoustic couplant is no longer necessary since sol-gel composite films establish high acoustic bonding with the substrates during the fabrication process. Furthermore, it is possible to fabricate sol-gel composite films on targets with complex geometry by using the spray technique [10,11,12,13,14,15,16]. Therefore, sol-gel composite ultrasonic transducers are applicable for industrial ultrasonic NDT at elevated temperatures.…”

Section: Introductionmentioning

confidence: 99%

Mn-Doped CaBi4Ti4O15/Pb(Zr,Ti)O3 Ultrasonic Transducers for Continuous Monitoring at Elevated Temperatures

Kobayashi

Kibe

Nagata

2017

Sensors

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Continuous ultrasonic in-situ monitoring for industrial applications is difficult owing to the high operating temperatures in industrial fields. It is expected that ultrasonic transducers consisting of a CaBi4Ti4O15(CBT)/Pb(Zr,Ti)O3(PZT) sol-gel composite could be one solution for ultrasonic nondestructive testing (NDT) above 500 °C because no couplant is required and CBT has a high Curie temperature. To verify the high temperature durability, CBT/PZT sol-gel composite films were fabricated on titanium substrates by spray coating, and the CBT/PZT samples were tested in a furnace at various temperatures. Reflected echoes with a high signal-to-noise ratio were observed up to 600 °C. A thermal cycle test was conducted from room temperature to 600 °C, and no significant deterioration was found after the second thermal cycle. To investigate the long-term high-temperature durability, a CBT/PZT ultrasonic transducer was tested in the furnace at 600 °C for 36 h. Ultrasonic responses were recorded every 3 h, and the sensitivity and signal-to-noise ratio were stable throughout the experiment.

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“…Further studies have found that process states derived from tooling-embedded sensors [7] provided information about process performance for prediction of variations of the machined part quality. These findings motivate research on embedded, multiparameter sensing, and effective data transmission methods.…”

Section: Introductionmentioning

confidence: 99%

Acoustic Wave-Based Data Transmission for Multivariate Sensing

Fan

Gao

Asadizanjani

et al. 2013

IEEE Trans. Instrum. Meas.

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Improving process observability is of high relevancy to improved manufacturing process control. This paper describes a novel measurement technique using acoustic waves for the transmission of multiple physical parameters from within the cavity of an injection mold to a receiver outside: temperature, pressure, velocity, and viscosity of polymer melt. Such a technique is a key to improved monitoring and control of plastic injection molding. A coded-acoustic wave modulation scheme enables multiparameter transmission through an acoustic transmitter with variable gains. This enables selective resonant frequencies that provide the carriers for the individual parameters to be transmitted, while suppressing noise induced in the modulation process. The presented acoustic wireless sensing method is applicable to a wide range of process monitoring scenarios.

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High-temperature piezoelectric film ultrasonic transducers by a sol-gel spray technique and their application to process monitoring of polymer injection molding

Cited by 34 publications

References 16 publications

Effect of sintering temperature on adhesion of spray-on piezoelectric transducers

Effect of sintering temperature on adhesion of spray-on piezoelectric transducers

Mn-Doped CaBi4Ti4O15/Pb(Zr,Ti)O3 Ultrasonic Transducers for Continuous Monitoring at Elevated Temperatures

Acoustic Wave-Based Data Transmission for Multivariate Sensing

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