Lead-Free AE Sensor Based on BZT–BCT Ceramics

In this study, an acoustic emission (AE) sensor was fabricated using lead-free Ba(Zr0.2Ti0.8)O3–0.5(Ba0.7Ca0.3)TiO3 (BZT–BCT) ceramics. The acoustic and electromechanical properties of the AE sensor were determined by the shapes of the piezoelectric ceramics. To optimize the AE sensor performance, the shapes of the ceramics were designed according to various diameter/thickness ratios (D/T) = 0.5, 1.0, 1.5, 2.0, 2.5, 3.0. The BZT–BCT ceramic with D/T = 1.0 exhibited excellent values of a piezoelectric charge coefficient (d33), piezoelectric voltage coefficient (g33), and electromechanical coupling factor (kp), which were 370 (pC/N), 11.3 (10−3 Vm/N), and 0.58, respectively. Optimum values of resonant frequency (fr) = 172.724 (kHz), anti-resonant frequency (fa) = 196.067 (kHz), and effective electromechanical coupling factor (keff) = 0.473 were obtained for the manufactured BZT–BCT ceramic with D/T = 1.0. The maximum sensitivity and frequency of the AE sensor made of the BZT–BCT ceramic with a D/T ratio of 1.0 were 65 dB and 30 kHz, respectively.