Smart piezoelectric composite: impact of piezoelectric ceramic microparticles embedded in heat-treated 7075-T651 aluminium alloy

Abstract Significant advances have been made in material synthesis in the last two decades, with a focus on polymers, ceramics, metals, and smart materials. Piezoelectric-based smart materials generate an electric voltage in response to loads, enabling distributed monitoring in critical structural parts. Friction stir processing (FSP) is a versatile approach that can enhance material performance in various engineering fields. The primary objective of the current research is to examine the sensorial properties of heat-treated AA7075-T651 aluminium plates that have been included with Lead Zirconate Titanate (PZT) and Barium Titanate (BT) particles via FSP. This study includes a comparative analysis of sensitivities with AA5083-H111 self-sensing material, metallographic and physicochemical characterization, and an assessment of the mechanical properties impacted by the incorporation of piezoelectric particles. The sensitivity of AA7075-PZT was found to be significantly higher than that of AA7075-BT. AA7075-PZT achieved a maximum sensitivity of 15.27 × 10 −4 μV/MPa while AA7075-BT had a sensitivity of only 7.28 × 10 −4 μV/MPa, which is 52% lower. Microhardness and uniaxial tensile tests demonstrated that the presence of particles has an influence on both mechanical strength and electrical conductivity of aluminium components, as opposed to those that do not have particles. The complete investigation intends to give significant insights into the performance and prospective uses of these innovative smart materials, therefore advancing materials science and engineering. Graphical abstract