Smart aluminum components: Printed sensors for integration into aluminum during high-pressure casting
Smart aluminum components: Printed sensors for integration into aluminum during high-pressure casting
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DOI：
10.1016/j.jmapro.2017.02.006
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发表时间：
2017-04
影响因子：
6.2
通讯作者：
G. Dumstorff;C. Pille;Rico Tiedemann;M. Busse;W. Lang
中科院分区：
文献类型：
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作者：
G. Dumstorff;C. Pille;Rico Tiedemann;M. Busse;W. Lang
我们提出了一种新的创新方法，可在铸造过程中将传感器直接集成到铝中，以获得铝的应变和温度数据。该技术将实现传感技术的各种新应用，例如汽车工业中的传感汽车部件（例如悬架臂）、具有用于反馈信息的集成传感器的外骨骼创新部件，或传感车辆的结构部件。此外，这些传感器可以实现更有效的质量保证，完全封装以防止环境影响，由于集成在铸造过程中而在传感器和金属基体之间提供理想的连接，并使工程师能够不受限制地直接将传感器放置在感兴趣的地方。为了实现在铝中集成传感器的目标，我们首先关注硅基传感器。我们将证明传感器集成是可能的，但故障率很高。这是通过评估铸造期间的传感器数据来分析的。由于铝和硅之间的热膨胀系数差异较大，硅中会产生较高的热致压应力，并在铸造过程中的凝固冷却过程中被破坏。这就是为什么我们在本文的第二部分中转换为新的传感器概念，该概念适应铸造工艺的条件。传感器及其电气连接印刷在铝板上，并通过工业高压铸造工艺集成在铝中。这些预测试的结果是，超过四分之三的设备在集成过程中幸存下来。最后，我们展示了从铸件中获取应变和温度数据，以开发铸铝智能组件并实现新的传感技术。
We present a new and innovative approach for the direct integration of sensors into aluminum during casting to obtain strain and temperature data for the aluminum. This technology will enable a variety of new applications in sensing technology such as sensing car parts in the automotive industries (e.g., a suspension arm), innovative parts of an exoskeleton with integrated sensors for feedback information, or sensing structural components of vehicles. Furthermore, these sensors can result in more efficient quality assurance, are fully encapsulated against environmental influence, provide an ideal connection between sensor and metal matrix due to integration in the casting process, and enable engineers to place sensors directly at the place of interest without limitations. To reach the goal of integrating sensors in aluminum, we first focus on silicon-based sensors. We will show that sensor integration is possible, but the failure rate is high. This is analyzed by evaluating sensor data during casting. Due to the high difference in coefficiency of thermal expansion between aluminum and silicon, high thermal-induced compressive stress is generated in the silicon and is destroyed in the casting process during solidification cooling. This is why we convert in the second part of this paper to a new sensor concept, which is adapted to the conditions of the casting process. A sensor and its electrical connections are printed on aluminum sheets and integrated in aluminum in an industrial high-pressure casting process. As a result of these pre-tests, more than three-quarters of the devices survived the process of integration. Finally, we show that we obtain strain and temperature data from the cast part to develop smart components out of cast aluminum and to enable new sensing technologies.