High‐Volume Production‐Compatible Technologies for Light Metal and Fiber Composite‐Based Components with Integrated Piezoceramic Sensors and Actuators

Abstract

Globalization, the scarcity of resources and climate change constantly raise new questions in the field of production engineering. One promising approach to the challenges involved is to reduce component weight with the aid of lightweight design. The integration of sensors and actuators made of “smart materials” into lightweight composites facilitates enhanced characteristics and functions such as ultra‐lightweight design, superior dynamic properties, and structural health monitoring. This essay presents the strategy adopted by Collaborative Research Center/Transregio 39 “High‐volume compatible production technologies for light metal and fiber composite‐based components with integrated sensors and actuators” (PT‐PIESA) in connection with research and development targeting the acquisition of the requisite scientific fundamentals. It also presents a concept for the holistic analysis of complex process chains for function‐integrated lightweight components with embedded piezoceramic elements.

Function‐integrative Lightweight Engineering – Design Methods and Applications

“…Nevertheless, the exact positioning of the sensors and the robustness of the integration and electric insulation must be guaranteed. In this context, functional layers consisting of electrical isolating carrier layers, sensor and/or actuator elements and conducting paths as well as connectors are developed that enable a precise positioning, robust manufacturing, and a robust operation , , . Fig.…”

“…In addition to various passive tasks, function‐integrative components increasingly fulfill sensor and actuator functions. These may be used advantageously, e.g., for structural health monitoring (SHM) and structural health control (SHC) concepts, especially in highly stressed lightweight structures . Such complex integral components, which take over a multitude of structural, functional and logic tasks, have to be generated by the individual combination of processes, materials and specific elements .…”

Delamination Behaviour of Embedded Polymeric Sensor and Actuator Carrier Layers in Epoxy Based CFRP Laminates—A Study of Energy Release Rates

“…The relatively new group of textile-reinforced plastics offers particular advantages for complex applications, espe-cially in the fields of aerospace, automotive, marine and mechanical engineering, medical technology and sports equipment [4][5][6]. In this context, such parts were further modified by adhesively bonding of additional functional elements to the composite structure or integrating them into the composite lay-up [7][8][9][10][11][12][13][14]. In most cases, these elements represent sensors, actuators, conductive paths, and small electronic elements.…”

“…However, the opportunities offered by this modern combination of materials also present new challenges that the fibre composite engineer has to face. This also includes manufacturing-specific aspects such as the integration of sensor and actuator elements into the structure of fibre composite components and its influence on the manufacturing or design process as well as on the mechanical properties [9,20,21]. In this context, several studies were made with regard to designing suitable smart components [9,22,23], adapted manufacturing technologies for function-integrative structures [17,24] and their experimental characterization [15,25,26].…”

“…This also includes manufacturing-specific aspects such as the integration of sensor and actuator elements into the structure of fibre composite components and its influence on the manufacturing or design process as well as on the mechanical properties [9,20,21]. In this context, several studies were made with regard to designing suitable smart components [9,22,23], adapted manufacturing technologies for function-integrative structures [17,24] and their experimental characterization [15,25,26]. Common materials are composites of glass fiber reinforced thermosets (mainly epoxy resins) or thermoplastics (e.g., polyamides, polypropylene).…”