Continuous ultrasonic in-situ monitoring for industrial applications is difficult owing to the high operating temperatures in industrial fields. It is expected that ultrasonic transducers consisting of CaBi4Ti4O15(CBT)/Pb(Zr,Ti)O3(PZT) sol-gel composite could be one solution for ultrasonic nondestructive testing (NDT) above 500 C because no couplant is required and CBT has a high Curie temperature. To verify the high temperature durability, CBT/PZT sol-gel composite films were fabricated on titanium substrates by spray coating, and the CBT/PZT samples were tested in a furnace at various temperatures. Reflected echoes with a high signal-to-noise ratio were observed up to 600 C. A thermal cycle test was conducted from room temperature to 600 C, and no significant deterioration was found after the second thermal cycle. To investigate the long-term high-temperature durability, a CBT/PZT ultrasonic transducer was tested in the furnace at 600 °C for 36 h. Ultrasonic responses were recorded every 3 h, and the sensitivity and signal-to-noise ratio were stable throughout the experiment.

The effects of the dielectric constant of the powder phase on lead zirconate titanate (PZT)/PZT sol-gel composite films were investigated to tailor their electrical properties. Three types of PZT powders were used to fabricate three different PZT/PZT sol-gel composite films. The PZT powders had the same electromechanical coupling coefficient but different relative dielectric constants. The PZT/PZT films were fabricated on a 3 mm-thick titanium substrate using an automatic spray coating system, and their properties were investigated. The relative dielectric constants of the PZT/PZT films were successfully controlled by tailoring the properties of the PZT powder phase. However, the piezoelectric constants showed a tendency different to those of the raw powders, because of the poor poling degree. This was overcome by conducting poling at a high temperature.