Fabrication Method for Series Production of Sheet Metal Parts with Integrated Piezoelectric Transducers

Nestler, Matthias; Drossel, Welf‐Guntram; Hensel, Sebastian; Müller, Roland

doi:10.1016/j.protcy.2014.09.009

Cited by 4 publications

(1 citation statement)

References 15 publications

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“…The proposed process chain combines active materials with the sandwich build-up. Earlier investigations showed, that these parts offer a sensor and actuator functionality and hence allow a reduction of vibrations and noise as well as the health-monitoring of a screwed connection in a demonstrative wing structure [9,10]. This paper focuses on the manufacturing method and general requirements for the production process.…”

Section: Introductionmentioning

confidence: 99%

Requirements for a Process Chain for Manufacturing of Piezoceramic-Aluminum Sandwiches

Nestler

Hensel

Drossel

et al. 2015

MSF

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Lightweight solutions and functional integration become more and more important in different fields of industry. In order to achieve a sensor and actuator functionality of shaped sheet metal parts, today a generally manual application step of the piezomodule is necessary. This subsequent process is time consuming and leads to high costs. In earlier studies a method was presented allowing the fabrication of a formable compound with an integrated sensor and actuator functionality. The formability of the compound is achieved using a viscous adhesive, surrounding the piezomodule during the forming operation. The low viscosity of the adhesive allows a relative movement between the piezomodule and the sheet metals and drastically reduces the transfer of critical strains to the piezomodule. Curing of adhesive takes place after the forming operation. To improve the efficiency of the process chain an advanced adhesive system with robust application properties has to be used. Furthermore, the productivity of several fabrication steps and their sequence in the process chain have to be verified and improved. The paper presents the process chain designed for automated production of formable sandwich sheets with integrated piezomodules, including the production steps for the fabrication of the semi-finished part as well as the forming operation. Aiming on a good formability during the shaping operation and on a stiff connection between the piezomodule and the sheet metal in the finished sandwich part, one focus is set on the adhesive properties required during the different process steps.

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Section: Introductionmentioning

confidence: 99%

Requirements for a Process Chain for Manufacturing of Piezoceramic-Aluminum Sandwiches

Nestler

Hensel

Drossel

et al. 2015

MSF

Self Cite

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3‐D Scanning Acoustic Microscope for Investigation of Curved‐Structured Smart Material Compounds

Wüst

Rupitsch

2018

Adv Eng Mater

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In this contribution, a system for acoustic microscopy to investigate complex‐shaped composite‐based components with integrated piezoceramic sensors or actuators is presented by the authors. Since piezoelectric materials are oftentimes lead‐containing, X‐ray based imaging is not always suitable to evaluate the inner structures of the piezoceramics. Thus, an adapted acoustic microscope for investigations of curved structures is introduced by the authors. High‐frequency ultrasonic imaging is a capable method to visualize cracks as well as delaminations because of refraction effects at the edges of a crack and changing reflection properties, respectively. Imaging results of curved structured specimens, which have been produced within the framework of the three different process chains of the CRC/TR 39: Metal forming, fiber composite, and aluminum die casting are presented by the authors.

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Thermally Controlled Adhesive Curing during the Production of Piezo‐Metal‐Compounds: Finite Element Modeling and Analyses

Landgraf

Ihlemann

2018

Adv Eng Mater

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In this paper, finite element (FE) analyses of the production process of piezo‐metal‐compounds are considered. The compounds consist of two adhesively bonded metal sheets with embedded actuator/sensor patches. During the production process, the patches are placed inside an uncured adhesive layer and the prepared compound is formed to its final shape, while the uncured adhesive serves as a floating support and protects the actuator/sensor patch. Only after forming, the adhesive is fully cured in order to achieve a complete load transfer between the structure and the actuator/sensor patch. For the described production process, two different adhesives are investigated within finite element simulations: a cold‐curing, two‐component, epoxy based adhesive, and a heat‐curing, one‐component polyurethane adhesive. Both adhesives have already been investigated by different experimental methods to obtain the thermal, chemical, and mechanical properties and to formulate corresponding phenomenological models. Moreover, these models are implemented into the FE software ANSYS. This paper concentrates on the FE modeling and corresponding analyses of the spatially and temporally controlled thermal activation during the production process of piezo‐metal‐compounds. The basic applicability of both adhesive systems is evaluated and suitable ranges for process parameters, like temperature ranges or the duration of dwell times, are given.

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Fabrication Method for Series Production of Sheet Metal Parts with Integrated Piezoelectric Transducers

Cited by 4 publications

References 15 publications

Requirements for a Process Chain for Manufacturing of Piezoceramic-Aluminum Sandwiches

Requirements for a Process Chain for Manufacturing of Piezoceramic-Aluminum Sandwiches

3‐D Scanning Acoustic Microscope for Investigation of Curved‐Structured Smart Material Compounds

Thermally Controlled Adhesive Curing during the Production of Piezo‐Metal‐Compounds: Finite Element Modeling and Analyses

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