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<p>To address the coupling errors induced by adhesive layers in conventional piezoelectric sensors, this study proposes a novel smart bolt integrated with a ZnO piezoelectric thin-film sensor (PTFS) deposited directly on the bolt head surface via magnetron sputtering. A theoretical model is established based on the piezoelectric effect and energy conservation principles, demonstrating a linear relationship between the piezoelectric output voltage and applied bolt torque. The ZnO PTFS was fabricated without adhesives, and its microstructure, composition, and piezoelectric properties were systematically characterized using XRD, EDS, SEM, and AFM. Results confirm that the sensor exhibits excellent crystallographic orientation (dominant (002) peak), high purity (EDS atomic ratio Zn/O ≈ 1:1), and strong film-to-substrate adhesion (critical load: 4646&#xa0;mN). Experimental tests reveal a longitudinal piezoelectric coefficient (d<sub>33</sub>) of 1.58&#xa0;pC/N and a torque sensitivity of 1.11&#xa0;mV/N&#xa0;m within the safe torque range (10-80&#xa0;N·m), with the output voltage showing a linear trend (<i>R</i><sup>2</sup> &gt; 0.97). The proposed smart bolt eliminates the need for skilled installation and adhesive-dependent coupling, offering enhanced reliability for structural health monitoring in aerospace and precision engineering applications.</p>

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Adhesive-Free ZnO Piezoelectric Thin-Film Smart Bolt for Torque Sensing and Structural Health Monitoring

  • 期刊论文

  • 发表日期：

    2026年7月21日

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  • Guowei Mo,
  • Hui Yu,
  • Weiqiang Liao,
  • Jian Gao

摘要

To address the coupling errors induced by adhesive layers in conventional piezoelectric sensors, this study proposes a novel smart bolt integrated with a ZnO piezoelectric thin-film sensor (PTFS) deposited directly on the bolt head surface via magnetron sputtering. A theoretical model is established based on the piezoelectric effect and energy conservation principles, demonstrating a linear relationship between the piezoelectric output voltage and applied bolt torque. The ZnO PTFS was fabricated without adhesives, and its microstructure, composition, and piezoelectric properties were systematically characterized using XRD, EDS, SEM, and AFM. Results confirm that the sensor exhibits excellent crystallographic orientation (dominant (002) peak), high purity (EDS atomic ratio Zn/O ≈ 1:1), and strong film-to-substrate adhesion (critical load: 4646 mN). Experimental tests reveal a longitudinal piezoelectric coefficient (d33) of 1.58 pC/N and a torque sensitivity of 1.11 mV/N m within the safe torque range (10-80 N·m), with the output voltage showing a linear trend (R2 > 0.97). The proposed smart bolt eliminates the need for skilled installation and adhesive-dependent coupling, offering enhanced reliability for structural health monitoring in aerospace and precision engineering applications.