Integrating Electronic Components, Sensors and Actuators in Cast Metal Components: An Overview of the State of the Art

Thick Film Sensor Manufacturing Techniques for Realization of Smart Components via Low Pressure Die Casting

“…In low pressure die casting, the complete sensor must endure high temperatures and thermal stresses during casting, in the course of which it is engulfed by molten aluminum reaching temperatures between 620 and 730 °C [5]. Therefore, it is manufactured on top of a 1.5 mm thick AlMg3 sheet (160 x 30 mm) and fully encapsulated.…”

“…However, the harsh processing conditions, which, depending on casting process and material, entail exposure to high temperatures and mechanical loads. A broad overview of the respective research area has recently been published by Lehmhus et al [5].…”

Advances in Metal Casting Technology: A Review of State of the Art, Challenges and Trends—Part II: Technologies New and Revived

“…The reason is not necessarily a lack of interest in the field but rather the difficulties linked to the comparatively high process temperatures in metal casting, which afford specific protective measures. Lehmhus et al recently suggested a classification of such approaches distinguishing between the four generalized principles illustrated in Figure 9 below [247].…”

“…What is apparent from this collection is that in most cases, a combination of the enabling measures, namely simplify, distribute, harden and protect, is employed. How to enable sensors and electronic systems to survive integration in metal castings-general principles: Top left, simplify-example of a rip wire sensor [247]; top right, distribute-integrate just those components that need to be integrated [248]; bottom left, harden-use materials that can withstand the process loads [249]; bottom right, protect-shield the integrated system against thermal and/or mechanical loads [250].…”

“…Needless to say, knowledge about the state of a component and/or the loads it has seen can also help form decisions about its suitability for potential reuse once the overall system has reached the end of its service life. Further investigations on the overarching topic of sensor integration in metal casting are available from Lehmhus et al, providing an overview of additional application scenarios as well as a more detailed description of selected technological approaches, including combined thick and thin film techniques for sensor deposition via screen printing [247,260]. From its humble beginnings, casting simulation has developed into a standard technique used by the majority of producers of castings as well as designers of molds over the last 30-40 years [271].…”