Patterned Metal Flexible Films as a Strain Sensor with Good Durability and Anti-Corrosion Property

To prevent corrosion in humid environments and electrical failure under loads, we developed a highly durable corrosion-resistant flexible strain sensor with a patterned sandwich structure. The effects of film dimensions and ambient temperature on the sensor’s electrical conductivity were investigated separately. The patterned flexible strain sensor demonstrated exceptional durability, maintaining stability after multiple tensile cycles and large deformations. The PDMS coating effectively protected the conductive layer from external environmental factors. Experimental results revealed that the sensor could efficiently block the corrosive effects of humid environments. Furthermore, when applied to real-time micro-strain detection in steel plate tensile tests, the relationship between ΔR/R0 and strain exhibited high linearity and sensitivity. The conductive film shows excellent durability and corrosion resistance, demonstrating significant application potential as a flexible strain sensor in humid conditions.