Integration of PZT-Ceramic Modules using Hybrid Structures in High Pressure Die Casting

High pressure die casting (HPDC) is one of the most suitable fabrication processes for complex shaped and thin walled castings. Applied in transport vehicles vibrations can occur due to weight-optimized component designs. Potential noise exposure can be avoided by the integration of smart materials. Contrary to an application on the component surface, the functional module is protected against external influences and force/form-fitted in the casting. Using HPDC is a challenging approach due to high thermal and mechanical loads during the fabrication cycle. In addition, the module has to be firmly connected to the aluminum matrix. Subsequent to the casting process, active Zn-coatings are applied. Results are presented, which exhibit a damage free integration of the smart components and the formation of diffusion zones between casting matrix and hybrid support structure.