Room-temperature fabricated magnetoelectric heterostructures for energy harvesting with aerosol-deposited barium titanate films on iron–cobalt/nickel substrates

As digital transformation continues to evolve, demand for battery-free sensors is rising. This study examines the manufacturing and energy-harvesting performance of magnetoelectric (ME) composites that combine piezoelectric and magnetostrictive materials using the aerosol deposition (AD) method, which enables room-temperature film fabrication. A barium titanate piezoelectric film was applied to a magnetostrictive clad plate of iron–cobalt (Fe–Co) and nickel (Ni). The composite, exposed to an alternating magnetic field, vibrated via magnetostrition. Voltage output and stored energy were measured to assess energy-harvesting capacity. Theoretical equations were derived for the optimal piezoelectric-film length and the corresponding harvested energy. Finite element analysis compared theoretical, numerical, and experimental results. The AD process preserved the magnetostrictive properties of the clad substrate while allowing coupled piezoelectric and magnetostrictive responses. The maximum harvested energy reached 193 nJ. Mechanical deformation of the piezoelectric film under alternating magnetic excitation generated an alternating voltage, confirming magnetic-to-electric energy conversion. The highest magnetoelectric voltage coefficient was 4.5 V·cm −1 ·Oe −1 (μV·m −1 ·T −1 ). Theory indicated that maximum power is obtained when the piezoelectric film covers two-thirds of the substrate length, a result supported by simulation and experiment. These findings demonstrate the practicality of AD-fabricated ME composites for compact, self-powered sensors in next-generation intelligent systems. • AD enabled room-temperature fabrication of magnetoelectric composites • BTO films on Fe-Co/Ni substrates preserved magnetostrictive properties • Maximum harvested energy of 193 nJ under alternating magnetic fields • Peak ME voltage coefficient of 4.5 V/cm·Oe achieved experimentally • Optimal piezoelectric film length is two-thirds of substrate length