SINA - Sensor integration in aluminum die casting

铝压铸中的SINA-传感器集成生产金属零件的最重要的技术是铸造。金属零件往往采用承重功能，同时承受较高的热应力和机械应力。他们的失败是市长的安全风险。对此，通过传感器监测它们的功能似乎是合适的。理想情况下，传感器应该直接嵌入金属中。研究现状表明，在金属零件中集成传感功能具有重要意义。到目前为止，由于铸件的高温和冷却过程中的热机械应力，在铸造过程中将传感器元件集成到金属中势必会失败。传感器元件在埋入过程中受到损坏或损坏。所要求的项目首次调查了传感器和铸造技术的创新组合。其目的是在铸造时为金属零件配备传感器功能。具体地，研究了压阻式应变传感器在铝压铸中的集成。研究了几种材料组合和工艺流程，以满足极高温度(数百℃)和高压的边界条件。进行了数值仿真，对传感器元件进行了加工、嵌入和分析。对其损伤机理进行了研究。开发了嵌入式传感器元件的电气互连的安装技术。嵌入的传感器在材料中充当异物，这可能会降低机械强度。通过数值模拟和显微镜、显微照片、拉弯试验和动态疲劳试验，从理论上研究了这一效应。为了确定传感器在金属中的位置，提出了定位的概念。利用有限元分析，开发了热载荷和机械载荷模式，并将其用于改进传感器元件的布局。

SINA - Sensor integration in aluminum die casting The most important technology to produce metal parts is casting. Metal parts often adopt load-bearing function and are subject to high thermal and mechanical stress at the same time. Their failure is a mayor security risk. Regarding this it seems appropriate to monitor their function by sensors. Ideally, the sensor should be embedded directly in the metal. The state of research shows the high importance of integrating sensing function in metal parts. Up to now, integrating sensor elements in metals during casting was bound to fail due to the high temperatures of casting and due to the thermomechanic stress during cooling down. The sensor elements were harmed or broken during embedding. The requested project investigates for the first time an innovative combination of sensor and casting technology. The aim is to equip metal parts with sensor function already while they are casted. Specifically, the integration of piezoresistive strain sensors in aluminum die casting is investigated. Several material combinations and technological process flows are investigated to meet the boundary conditions of very high temperature (several hundred °C) and high pressure. Numerical simulations are performed, sensor elements are processed, embedded and analyzed. The damage mechanisms are investigated. Mounting technologies for the electrical interconnection of the embedded sensor elements are developed. The embedded sensor acts as a foreign body in the material which may downgrade the mechanical strength. This effect is investigated theoretically using numeric simulation and experimentally using microscopy, micrographs, pull- and bending-test, and dynamic fatigue tests. In order to get a definite positioning of the sensors in the metal, concepts for positioning are developed. Using Finite Element Analysis, thermal and mechanical load patterns are developed and used to improve the layout of the sensor elements.