The authors would like also to thank to Micronsense-Metrologia Industrial (Leiria, Portugal) for the μCT analysis. The authors would also like to thank Prof. Catarina Santos for granting access to the MicroLab - Electron Microscopy Laboratory (Instituto Superior Técnico) for the SEM analyses.Structural Health Monitoring systems assess the part's current condition. This can be performed with a monitoring system comprising sensors, on the surface or embedded, in the monitored parts. However, surface sensors are subject to damage, and embedding the sensors may result in a weakened part. An innovative Self-Sensing Material and its manufacturing process were developed and are presented herein. As proof of concept, Barium Titanate particles were introduced and dispersed into an AA5083-H111 part by Friction Stir Processing (FSP). The particles’ distribution and concentration was evaluated by a set of characterization techniques, demonstrating that greater concentrations, grant enhanced sensitivity to the material. The use of FSP and the embedded particles improved the part’s mechanical behaviour in the processed zone. The sensorial properties were assessed and the response to a set of dynamic loads was measured, being coherent with the solicitations provided. The developed self-sensing material revealed an electrical sensitivity of 12.0 × 10-4 uV/MPa.publishersversionpublishe
