Smart structural components by integration of sensor/actuator-modules in die castings

The integration of piezoceramic based sensors and actuators offers a possibility to produce multifunctional materials with enhanced properties. Die casting is an innovative approach for the fabrication of metal matrix smart structural components where the functional module is totally integrated in the interior of the cast part. A technique to support and protect the sensitive sensor/actuator-modules in the die during the highly dynamic die filling process is presented. Demonstration parts were produced which are fully capable to be activated to vibrate. An approach to characterize in detail the behavior of the sensor/actuator-module after the integration in the cast matrix is presented. Both FE computation and electric impedance measurements are used to quantify how the casting process affects the performance of the integrated sensor/actuator-modules.