Active functionality of piezoceramic modules integrated in aluminum high pressure die castings

• PZT-modules embedded into aluminum high pressure die castings.
• No damage of functional element despite of harsh casting conditions.
• Different positions of the PZT-modules in the casting can be realized.
• Integrated actuators can reach a relative functionality of 90%.
• Functionality decreases with increasing wall thickness.

Based on high pressure die casting (hpdc) technology, this study deals with the integration of piezoceramic modules into aluminum castings. Despite of the severe thermal and mechanical loads during the casting process, a successful integration of polymer based piezoceramic modules is possible. Measurements show the influence of the distance of the module to the neutral axis on the functionality. In addition wall thickness influences the performance of the module. In order to quantify the efficiency of the actuatoric functionality in the integrated state, a beam bending model is used. A comparison of the theoretical to the experimental behavior shows nearly no loss of module performance in thin-walled parts but a decrease of the performance with increasing wall thickness.