Active Vibration Damping in Structural Aluminum Die Castings via Piezoelectricity – Technology and Characterization

Abstract

Piezoelectric modules are integrated in structural aluminum components (AlSi9Cu3(Fe)) using highpressure die casting for damping purposes. Investigations using X-ray analysis indicate a damage free integration and good casting quality despite very harsh casting conditions. FE simulations provide information about the mode shapes of the casting and could be confirmed by investigations using a 3D laser scanning vibrometer (LSV). Frequency sweeps show that many modes are stimulated by applying voltage to the piezoelectric module. It is demonstrated, how an actively induced vibration signal in the casting is reduced by creating a phase-shifted counteracting vibration with the help of the integrated module. Fig. 11. LSV-measured surface velocities of the bell excited at the first natural frequency -977 Hz: (a) only shaker in action (b) shaker and compensation by piezoelectric module actuated in opposite phase. M. Schwankl et al./Active Vibration Damping in Al-HPDC Castings ADVANCED ENGINEERING MATERIALS 2015, 17, No. 7

New Materials and Processes for Transport Applications: Going Hybrid and Beyond

“…Possibly even more demanding is the integration of electronic components in high pressure die casting, as is exemplified by Figure f, which shows an HPDC component with integrated radio frequency identification (RFID) device, which may serve part identification in general as well as specific tasks like counteracting plagiarism. The concept as such, that is, integration of smart systems in HPDC, can also be extended to the use of sensors for monitoring tasks and may gain additional interest in a smart manufacturing and/or Internet of Things context . Besides, it can also be transferred to Additive Manufacturing for metallic components, and much more easily to polymer‐based materials and structures, as is widely illustrated, for example, by structural health monitoring (SHM) approaches in the aerospace or wind energy industry…”

Integration of piezoelectric stacks in components using powder bed fusion

“…The aim was to achieve mass production of piezoelectric-metal composites. A similar approach but with a different production technology was taken by Schwankl et al [4]. During die casting, a piezoelectric patch was integrated and successfully used for vibration damping of a thin-walled structure.…”

Experimental and numerical investigations regarding laser drop on demand jetting of Cu alloys

“…These composite assemblies with sensor and/or actuator functionalities thus became focus of interest of different engineering fields in recent years [2][3][4]. Since the electrical joints of the actuator modules need to withstand significant thermal loads of >600 °C, particularly during the casting process [5,6], a novel laser assisted bonding process has been developed, and is referred to as laser drop on demand joining. The Abstract Active noise reduction, structural health monitoring and energy harvesting are possible applications of active structure components.…”