TRR 39:  Production Technologies for Lightmetal and Fiber Reinforced Composite Based Components with Integrated Piezoceramic Sensors and Actuators (PT-PIESA)

• Subject Area: Mechanical and Industrial Engineering ; Computer Science, Systems and Electrical Engineering ; Materials Science and Engineering
• Term: from 2006 to 2018
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 21440441

The research objective of the Transregional Collaborative Research Centre is the development of manufacturing technologies for active structural components. These are characterised by the direct substantial integration of sensor-actuator-materials in a lightweight engineering material. The hitherto disconnected process chains of the component manufacturing and the manufacturing of applicable sensory or actuatory effective modules are to fuse. The substantial integration of the transformer material piezoceramic is immediately effected in the process of the component manufacturing. Thereby, high-volume manufacturing technologies for active structural components are developed. These technologies are a significant precondition for the introduction of adaptronic components to the industrial application.
Adaptronic components use the integrated sensors and actuators in combination with an adapted control and regulatory electronic to adapt their structural dynamical characteristics to the changes in loads taking effect on them. Thereby, the permanent design conflict in mechanical structures between geometry and loads on the one hand, and low weight and high structure damping on the other, can be reduced in such a dimension that cannot be accomplished with only a structural and substantial lightweight construction. Nowadays, the problem of two-dimensional lightweight construction structures can especially be found in the susceptibility to structure vibration and the noise emission caused by the reduced surface mass. In mechanical engineering the structure vibrations reduce the reachable dynamics and therefore, the productivity through the reduction of the machining quality, vibrating vehicle components reduce the comfort and passive additional measures increase the fuel consumption. Extreme noise pollution through an increased noise emission is a general environmental problem with a growing importance.
The profit and the very high application potential of adaptronics is an undoubted fact. The technical feasibility of the system approach has frequently been proven in national and international research projects. The conversion into products especially fails due to unavailable manufacturing technologies having the potential of a high-volume production. This problem holding a high innovation potential represents the research object of this Transregional Collaborative Research Centre.

• DFG Programme: CRC/Transregios

Completed projects

• A01 - Manufacturing Technologies of Functional Piezoelectric Components for Integration into Lightweight Structures (Project Heads Gebhardt, Sylvia ;  Michaelis, Alexander )
• A02 - Microstructuring and automated joining technologies for piezo fibers in metal carrier (Project Heads Koriath, Hans-Joachim ;  Schubert, Andreas )
• A03 - Thin film technologies and production technologies for active microstructured piezoelectric semi-finished parts (Project Heads Peter, Siegfried ;  Wittstock, Volker )
• A04 - Laser based electrical and mechanical contacting of composite materials with integrated active elements (Project Heads Roth, Stephan ;  Schmidt, Michael )
• A05 - Development of thermoplastic-compatible piezoceramic modules (TPM) and corresponding production processes (Project Head Gude, Maik )
• A06 - Manufacturing technology for piezo modules with integrated ceramic composites and functional polymers for the integration in active metallic devices (Project Heads Kroll, Lothar ;  Tröltzsch, Jürgen )
• B01 - Forming of piezo-metal-compounds and numerical investigation of shaping operation and its influence on functionality (Project Heads Drossel, Welf-Guntram ;  Müller, Roland )
• B02 - Numerical study of the influence of forming operation on function of piezo-metalcompounds (Project Heads Drossel, Welf-Guntram ;  Neugebauer, Reimund )
• B03 - Integration of piezoceramic modules into metallic components by casting - Technology and numerical simulation (Project Head Körner, Carolin )
• B04 - Robust manufacturing technologies for active thermoplastic composite structures with integrated piezoceramic modules (Project Head Modler, Niels )
• B05 - Montagespritzgießen von piezoaktiven Sandwichbauteilen (Project Head Schmachtenberg, Ernst )
• B06 - High-volume production technologies for glass fibre-reinforced polyurethane composite structures with integrated piezoceramic sensor elements and adapted electronics (Project Heads Fischer, Wolf-Joachim ;  Gude, Maik )
• C01 - FEM-basierte Entwicklung eines integrierten Auslegungs- und Funktionsmodells für flächige Piezofaser-Metall-Module zum Einsatz in durch Umformung hergestellten Blechstrukturen (Project Head Drossel, Welf-Guntram )
• C03 - Study of poling technology as part of series fabrication of smart structures (Project Heads Neumeister, Peter ;  Schönecker, Andreas )
• C06 - Material Characterization and Numerical Simulation of Adaptive Composites (Project Heads Lerch, Reinhard ;  Rupitsch, Stefan J. )
• C07 - Simulation of adhesives curing and shrinking processes within piezo-metalcomposites (Project Head Ihlemann, Jörn )
• C08 - Polarization Determination of Integrated Piezoceramics as Part of Process Control and Non-destructive Device Evaluation (Project Head Gerlach, Gerald )
• C09 - Model-based ultrasonic imaging for dimensional measurements of cracks within heterogeneous composite structures (Project Head Rupitsch, Stefan J. )
• T01 - Integration of piezo modules in rear axle components of passenger cars for active vibration control and reduction of gear noise (Project Head Drossel, Welf-Guntram )
• T02 - Plastic-based integration of functionalized substrates with piezo modules in components for high volume production (Project Head Kroll, Lothar )
• T03 - Design and manufacturing of fiber-reinforced structures with integrated actuator-sensor-arrays for technical measurement applications (Project Heads Dannemann, Martin ;  Modler, Niels )
• T04 - Development of a laser-assisted drop-on demand brazing process to extend the process limits of conventional wire bonding processes for electronics assembly and packaging (Project Heads Roth, Stephan ;  Schmidt, Michael )
• Z01 - Central Tasks (Project Head Drossel, Welf-Guntram )

• Applicant Institution: Technische Universität Chemnitz
• Co-Applicant Institution: Friedrich-Alexander-Universität Erlangen-Nürnberg; Technische Universität Dresden
• Participating Institution: Bayerisches Laserzentrum (BLZ) GmbH; Fraunhofer-Institut für Keramische Technologien und Systeme (IKTS); Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik (IWU)
• Spokesperson: Professor Dr.-Ing. Welf-Guntram Drossel