A. Fioravanti, Pietro Marani, Giorgio Paolo Massarotti, Stefano Lettieri, Sara Morandi, Maria Cristina Carotta, Fioravanti, A., Marani, P., Massarotti, G. P., Lettieri, S., Morandi, S., and Carotta, M. C.
The proper operation of a fluid power system in terms of efficiency and reliability is directly related to the fluid state, therefore, the monitoring of fluid ageing in real time is fundamental to prevent machine failures. For this aim, an innovative methodology based on fluid vapor analysis through metal oxide (shortened: MOX) gas sensors has been developed. Two apparatuses were designed and realized: (i) A dedicated test bench to fast-age the fluid under controlled conditions, (ii) a laboratory MOX sensor system to test the headspace of the aged fluid samples. To prepare the set of MOX gas sensors suitable to detect the analytes’ concentrations in the fluid headspace, different functional materials were synthesized in the form of nanopowders, characterizing them by electron microscopy and X-ray diffraction. The powders were deposited through screen-printing technology, realizing thick-film gas sensors on which dynamical responses in the presence of the fluid headspace were obtained. It resulted that gas sensors based on solid solution TixSn1–xO2 with x = 0.9 and 0.5 offered the best responses toward the fluid headspace with lower response and recovery times. Furthermore, a decrease in the responses (for all sensors) with fluid ageing was observed.