Development of hybrid assembled composites with sensory function

Kräusel, Verena; Graf, Adam; Heinrich, Michael; Decker, Ricardo; Caspar, Mirko; Kroll, Lothar; Hardt, Wolf‐Dietrich; Göschel, Angela

doi:10.1016/j.cirp.2015.04.054

Cited by 17 publications

(10 citation statements)

References 10 publications

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“…In [1] and [2], flat material composites are formed into hybrid laminates with sensor functionalities by roll cladding and subsequent deep drawing. The authors have verified the scalability of this technique for large-series production.…”

Section: Motivationmentioning

confidence: 99%

“…Brenneis [7] demonstrates that this principle works when swaging piezoceramic rings. Another approach consists of embedding piezoceramic particles into a thermoplastic matrix, see [1] and [2]. The thermoplastic matrix enables new manufacturing options for such composites.…”

Section: Motivationmentioning

confidence: 99%

“…Next, the finished laminate is polarized and characterized. The application-ready shape can be achieved by additional sheet forming processes such as deep drawing [1], [2]. The procedure for manufacturing functional elements according to Müller [3] provides another option: In this technique, microcavities are created in the aluminum sheet, which is joined with piezoceramic fibers, and the functional compound is subsequently deep-drawn.…”

Section: Introductionmentioning

confidence: 99%

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Extrusion of screws with sensor functionality

Graf

Guk

Birnbaum

et al. 2020

TLS

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The use of components with embedded sensors is one of the most promising trends in civil engineering, plant construction and mechanical engineering. These components make it possible to both monitor the design state in real time and to recognize failures in parts and components early on. However, due to high product costs, their wider distribution is limited. Optimization of the component manufacturing technology can contribute to reducing the production costs.Fasteners, such as screws and rivets, consisting of a polypropylene composite core filled with piezoceramic powder represent a potential approach. In the event of a sudden impact, this compound generates an electric pulse, and through machine learning the cause of the failure can be filtered out from the screw’s normal state.Simultaneous forming of aluminum and plastics opens up new opportunities to produce the abovementioned screws at a reasonable price. The authors’ aim was to demonstrate feasibility through initial experiments and the generation of a simulation model.

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Section: Motivationmentioning

confidence: 99%

Section: Motivationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Extrusion of screws with sensor functionality

Graf

Guk

Birnbaum

et al. 2020

TLS

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“…New approaches of passive sensing are based on online-capable SHM systems that combine advanced sensor technologies with intelligent algorithms and thus allow a diagnosis of the structural integrity of the monitored component [ 17 , 18 ]. In addition to improving component reliability and safety, maintenance intervals can be extended and maintenance costs reduced.…”

Section: Introductionmentioning

confidence: 99%

“…The PFML consists of a thermoplastic piezoelectric material which, in combination with the FML, creates a passive sensor system and therefore forms an integral part of the component. The basis for the mostly required large-scale production is thus a PFML, which is manufactured in a continuous production process [ 17 , 18 , 22 ].…”

Section: Introductionmentioning

confidence: 99%

Monitoring the Structural Health of Glass Fibre-Reinforced Hybrid Laminates Using Novel Piezoceramic Film

Schmidt

Graf

Decker

et al. 2020

Sensors

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This work investigates a new generation structural health monitoring (SHM) system for fibre metal laminates (FML) based on an embedded thermoplastic film with compounded piezoceramics, termed piezo-active fibre metal laminate (PFML). The PFML is manufactured using near-series processes and its potential as a passive SHM system is being investigated. A commercial Polyvinylidene fluoride (PVDF) sensor film is used for comparative evaluation of the sensor signals. Furthermore, thermoset and thermoplastic-based FML are equipped with the sensor films and evaluated. For this purpose, static and dynamic three-point bending tests are carried out and the data are recorded. The data obtained from the sensors and the testing machine are compared with the type and time of damage by means of intelligent signal processing. By using a smart sensor system, further investigations are planned which the differentiation between various failure modes, e.g., delamination or fibre breakage.

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Functionalized Compounds for Micro‐Injection Molded Piezo Modules (μIMP‐Modules) and Their Electrical Contacting

et al. 2018

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Multi‐component micro‐injection molding enables the manufacturing of active elements as well as electrical contacting in situ and in a single process by using piezo active and electroconductive plastic compounds. Each compound is functionalized with filler materials according to its special demands. To this end, polypropylene (PP) with an electromechanical active filler based on piezoceramic powder (PZT: Lead zirconate titanate) for sensor functionality as well as PP with electroconductive properties based on carbon nanotubes (CNT) and carbon black (CB) for electrical contacting are investigated. Therefore, different compound compositions are analyzed with regard to their mechanical and electrical properties as well as their mechanical compatibility. For the analyses, micro injection molded samples of the different compounds are used. Furthermore, investigations on composite strength are conducted by measuring interlaminar shear strength between the functionalized compounds. Based on the material characterization, a simulation of the thermomechanical behavior is done and the process‐related residual stresses are analyzed. To achieve the prerequisites for fabricating sensor modules in mass production, the functionalized compounds should be processed by means of the two‐component micro‐injection molding technology. According to this, the objective target is a large‐scale integration of these piezo modules into multifunctional lightweight structures. Therefore, the modules are combined with electrically functionalized textile substrates creating semi‐finished products with sensor functionalities. The mechanical and electrical connections are created by ultrasonic welding. Applying this technology requires a manufacturing study with varying process parameters of joining force, amplitude and welding time with the aim of achieving minimal electrical contact resistance.

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Development of hybrid assembled composites with sensory function

Cited by 17 publications

References 10 publications

Extrusion of screws with sensor functionality

Extrusion of screws with sensor functionality

Monitoring the Structural Health of Glass Fibre-Reinforced Hybrid Laminates Using Novel Piezoceramic Film

Functionalized Compounds for Micro‐Injection Molded Piezo Modules (μIMP‐Modules) and Their Electrical Contacting

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