Mechanical, Electrical, and Piezoresistive Sensing Characteristics of Epoxy-Based Composites Incorporating Hybridized Networks of Carbon Nanotubes, Graphene, Carbon Nanofibers, or Graphite Nanoplatelets

Experimental Investigation into the Mechanical and Piezoresistive Sensing Properties of Recycled Carbon-Fiber-Reinforced Polymer Composites for Self-Sensing Applications

This study investigates the mechanical and piezoresistive sensing properties of recycled carbon-fiber-reinforced polymer composites (rCFRPs) for self-sensing applications, which were prepared from recycled carbon fibers (rCFs) with fiber lengths of 6, 12, 18, and 24 mm using a vacuum infusion method. Mechanical properties of the rCFRPs were examined using uniaxial tensile tests, while sensing characteristics were examined by monitoring the in situ electrical resistance under cyclic and low fatigue loads. Longer fibers (24 mm) showed the superior tensile strength (92.6 MPa) and modulus (8.4 GPa), with improvements of 962.1% and 1061.1%, respectively. Shorter fibers (6 mm) demonstrated enhanced sensing capabilities with the highest sensitivity under low fatigue testing (1000 cycles at 10 MPa), showing an average maximum electrical resistance change rate of 0.7315% and a gauge factor of 4.5876. All the composites displayed a stable electrical response under cyclic and low fatigue loadings. These results provide insights into optimizing rCF incorporation, balancing structural integrity with self-sensing capabilities and contributing to the development of sustainable multifunctional materials.

Heating and Strain Sensing Elements Based on Segregated Polyethylene/Carbon Black Composites in Polymer Welded Joints

The development of easy and direct real-time monitoring of welded joint quality instead of surface damage analysis is crucial to improve the quality of industrial products. This work presents the results of high-density polyethylene (HDPE)-based composites with various carbon black (CB) content (from 20 to 30 vol.%) for use as a heating element and strain sensor in electrofusion-welded polymer joints. The pyroresistive heating process was used to determine the effect of generated Joule heat during welding on the structure and sensor properties of polymer-carbon composites. It is shown that the generation of Joule heat depends on the nanocarbon content and affects the crystallinity of the polymer matrix. The partial disruption of the conductive path of carbon black particles was observed and, as a result, a decrease in electrical conductivity for composites with lower CB content after welding was found. For the highest CB amount, conductivity increased, which is caused by smaller particle-to-particle distance for filler paths. Therefore, the best balance between pyroresistive and sensor properties was found.

Flexible Piezoresistive Polystyrene Composite Sensors Filled with Hollow 3D Graphitic Shells

The objective of this research was to develop highly effective conductive polymer composite (CPC) materials for flexible piezoresistive sensors, utilizing hollow three-dimensional graphitic shells as a highly conductive particulate component. Polystyrene (PS), a cost-effective and robust polymer widely used in various applications such as household appliances, electronics, automotive parts, packaging, and thermal insulation materials, was chosen as the polymer matrix. The hollow spherical three-dimensional graphitic shells (GS) were synthesized through chemical vapor deposition (CVD) with magnesium oxide (MgO) nanoparticles serving as a support, which was removed post-synthesis and employed as the conductive filler. Commercial multi-walled carbon nanotubes (CNTs) were used as a reference one-dimensional graphene material. The main focus of this study was to investigate the impact of the GS on the piezoresistive response of carbon/polymer composite thin films. The distribution and arrangement of GS and CNTs in the polymer matrix were analyzed using techniques such as X-ray diffraction and scanning electron microscopy, while the electrical, thermal, and mechanical properties of the composites were also evaluated. The results revealed that the PS composite films filled with GS exhibited a more pronounced piezoresistive response as compared to the CNT-based composites, despite their lower mechanical and thermal performance.

A Comprehensive Study on EMI Shielding Performance of Carbon Nanomaterials-Embedded CFRP or GFRP Composites

The rapid advancement of electrical and telecommunication facilities has resulted in increasing requirements for the development of electromagnetic interference (EMI) shielding composites. Accordingly, an experimental study was conducted to evaluate the EMI shielding performance of carbon nanomaterial (CNM)-embedded carbon-fiber-reinforced polymer (CFRP) or glass-fiber-reinforced polymer (GFRP) composites. Nine combinations of CNMs and carbon or glass fibers were used to fabricate the composites. The synergistic effects of CNMs on the EMI shielding performance were systematically investigated. The results indicated that plate-type CNMs (i.e., graphene and graphite nanoplatelets) have more prominent effects than fiber-type CNMs (carbon nanofibers). The composites fabricated with CFRP afforded higher EMI shielding than the GFRP-based composites. Among the eighteen samples, 3% CNT-GNP in CFRP composites, which included plate-typed CNM, exhibited the best EMI shielding performances, showing 38.6 dB at 0.7 GHz. This study helps understand the shielding performance of CNM-embedded CFRP and GFRP composites in electrical and telecommunication facilities.

Multiwalled Carbon Nanotube/Graphite Powder Film for Wearable Pressure Sensors with High Sensing Performance

With the continuous progress of artificial intelligence and other manufacturing technologies, there is promising potential for wearable piezoresistive sensors in human physiological signal detection and bionic robots. Here, we present a facile solution-mixing process to fabricate a multiwalled carbon nanotube/graphite powder (MWCNT@Gp) film, which has high sensitivity and great linearity and is more oriented to flexible piezoresistive sensors. The sensor consists of two parts: a spinosum microstructure shaped by a sandpaper template and polydimethylsiloxane (PDMS) as the top substrate and interdigital electrodes as the bottom substrate. The experiments we have conducted show that these two parts provide good protection to the MWCNTs@Gp film and improve sensor sensitivity. Additionally, the sensitivity of the optimal ratio of multiwalled carbon nanotubes and graphite powder is analyzed. The 5%MWCNT@5%Gp composites were found to have relatively good conductivity, which is convenient for the fabrication of conductive films of piezoresistive sensors. Finally, we conducted application experiments and found that the flexible piezoresistive sensor can detect minute signals of human motion and different pressure points. This indicates the feasibility of portable sensors in electronic skin and smart devices.

The status and perspectives of nanostructured materials and fabrication processes for wearable piezoresistive sensors

The wearable sensors have attracted a growing interest in different markets, including health, fitness, gaming, and entertainment, due to their outstanding characteristics of convenience, simplicity, accuracy, speed, and competitive price. The development of different types of wearable sensors was only possible due to advances in smart nanostructured materials with properties to detect changes in temperature, touch, pressure, movement, and humidity. Among the various sensing nanomaterials used in wearable sensors, the piezoresistive type has been extensively investigated and their potential have been demonstrated for different applications. In this review article, the current status and challenges of nanomaterials and fabrication processes for wearable piezoresistive sensors are presented in three parts. The first part focuses on the different types of sensing nanomaterials, namely, zero-dimensional (0D), one-dimensional (1D), two-dimensional (2D), and three-dimensional (3D) piezoresistive nanomaterials. Then, in second part, their fabrication processes and integration are discussed. Finally, the last part presents examples of wearable piezoresistive sensors and their applications.

A Comparative Study on the Electrical and Piezoresistive Sensing Characteristics of GFRP and CFRP Composites with Hybridized Incorporation of Carbon Nanotubes, Graphenes, Carbon Nanofibers, and Graphite Nanoplatelets

In this study, hybridized carbon nanomaterials (CNMs), such as carbon nanotubes (CNTs)–graphene, CNT–carbon nanofibers (CNFs), or CNT–graphite nanoplatelet (GNP) materials were embedded in glass-fiber-reinforced plastic (GFRP) or carbon-fiber-reinforced plastic (CFRP) composites to obtain electrical/piezoresistive sensing characteristics that surpass those of composites with only one type of CNM. In addition, to quantitatively assess their sensing characteristics, the materials were evaluated in terms of gauge factor, peak shift, and R-squared values. The electrical property results showed that the GFRP samples containing only CNTs or both CNTs and graphene exhibited higher electrical conductivity values than those of other composite samples. By evaluating piezoresistive sensing characteristics, the CNT–CNF GFRP composites showed the highest gauge factor values, followed by the CNT–graphene GFRP and CNT-only GFRP composites. These results are explained by the excluded volume theory. The peak shift and R-squared value results signified that the CNT–graphene GFRP composites exhibited the best sensing characteristics. Thus, the CNT–graphene GFRP composites would be the most feasible for use as FRP composite sensors.

A Study on Mechanical Characteristics of Cement Composites Fabricated with Nano-Silica and Carbon Nanotube

In this study, cement composites were fabricated with various contents of added nano-silica (NS) and multi-walled carbon nanotubes (MWNTs). The compressive and flexural strengths of the resultant cement composites were examined. To explore the microstructures and MWNT distribution, electrical conductivity tests, and scanning electron microscopy were conducted. In addition, the strength results were analyzed based on thermal analysis and porosity evaluations. The electrical conductivity results indicated that MWNTs were satisfactorily distributed in the cement composites. In the mechanical strength tests, the composite with a 0.6% MWNT and 5% NS content and another with a 0.3% MWNT and 5% NS content yielded enhancements in the compressive and flexural strengths of 17.2% and 52% compared with the control samples, respectively. However, composites containing relatively large amounts of both NS and MWNTs showed degradation in the mechanical strength. The enhancement or degradation of the strength was supported by porosity evaluations and thermal analysis results. In particular, the degradation of the strength due to the incorporation of large amounts of both MWNTs and NS was explained by thermogravimetric analysis, which indicated a limited generation of calcium silicate hydrate (C-S-H) hydration products. The lower generation of C-S-H was likely due to the dense microstructure of MWNT/NS-incorporated cement hindering the reactions between calcium hydroxide and the NS.

Smart Graphite-Cement Composite for Roadway-Integrated Weigh-In-Motion Sensing

Smart multifunctional composites exhibit enhanced physical and mechanical properties and can provide structures with new capabilities. The authors have recently initiated a research program aimed at developing new strain-sensing pavement materials enabling roadway-integrated weigh-in motion (WIM) sensing. The goal is to achieve an accurate WIM for infrastructure monitoring at lower costs and with enhanced durability compared to off-the-shelf solutions. Previous work was devoted to formulating a signal processing algorithm for estimating the axle number and weights, along with the vehicle speed based on the outputs of a piezoresistive pavement material deployed within a bridge deck. This work proposes and characterizes a suitable low-cost and highly scalable cement-based composite with strain-sensing capabilities and sufficient sensitivity to meet WIM signal requirements. Graphite cement-based smart composites are presented, and their electromechanical properties are investigated in view of their application to WIM. These composites are engineered for scalability owing to the ease of dispersion of the graphite powder in the cement matrix, and can thus be used to build smart sections of road pavements. The research presented in this paper consists of electromechanical tests performed on samples of different amounts of graphite for the identification of the optimal mix in terms of signal sensitivity. An optimum inclusion level of 20% by weight of cement is obtained and selected for the fabrication of a plate of 30 × 15 × 5 cm³. Results from load identification tests conducted on the plate show that the proposed technology is capable of WIM.

Applications of Graphene-Based Materials in Sensors

This Special Issue compiles a set of innovative developments on the use of graphene-based materials in the fabrication of sensors. In particular, these contributions report original studies on a wide variety of sensors, such as gas sensors for NO₂ or NH₃ detection, antibody biosensors or mass sensors. All these devices have one point in common: they have been built using graphene-based materials like graphene, graphene oxide, reduced graphene oxide, inkject printing graphene, graphene-based composite sponges, graphene screen-printed electrodes or graphene quantum dots.