Dynamic Response of a Polyvinylidene Fluoride (PVDF) Sensor Embedded in a Metal Structure Using Ultrasonic Additive Manufacturing

This study aims to examine the dynamic response of a polyvinylidene fluoride (PVDF) piezoelectric sensor which is embedded into an aluminum coupon using ultrasonic additive manufacturing (UAM). Traditional manufacturing techniques used to attach smart materials to metals on the surface have drawbacks, including the potential of exposing the sensor to adverse environments or physical degradation during manufacture. UAM can avoid these issues by integrating solid-state metal joining with subtractive processes to enable the fabrication of smart structures. A commercial PVDF sensor is embedded in aluminum with a compression technique to provide frictional coupling between the sensor and the metallic matrix. The PVDF sensor’s frequency bandwidth and impact detection performance are evaluated by conducting cantilever and axial impact tests, as well as harmonic excitation tests with an electrodynamic shaker. Under axial loading, the embedded sensor displays high linearity with a sensitivity of 43.7 mV/N, whereas impact tests in the cantilever configuration exhibit a steady decay rate of 0.13%. Finally, bending tests show good agreement between theoretical and experimental natural frequencies with percentage errors under 6% in two different clamping positions, and correspond to the maximum voltage output obtained from the embedded PVDF sensor at resonance.