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Encapsulating piezoresistive thin film sensors based on amorphous diamond-like carbon in aluminium castings

: Pille, C.; Biehl, S.; Busse, M.

Denkena, B.:
System-integrated intelligence: New challenges for product and production engineering : Proceedings of the first Joint International Symposium on System-Integrated Intelligence 2012, SYSINT2012. June 27th - 29th 2012 Hannover, Germany
Garbsen: PZH Produktionstechnisches Zentrum, 2012
ISBN: 978-3-943104-59-2
Joint International Symposium on System-Integrated Intelligence (SYSINT) <1, 2012, Hannover>
Fraunhofer IST ()
Fraunhofer IFAM ()
casting; aluminium; sensor integration; DLC thin film sensors; casttronics

The paper describes a new approach for the in-process integration of sensors into lightweight metal components made of aluminum, fabricated by casting. It examines the suitability of thin film sensors 'DiaForce®' based on piezoresistive hydrocarbon layers (DLC) for integration in molten aluminum. In contrast to previous research, a technology is introduced, which will allow real-time measurement both dynamic and static loads for the detection of permanent deformation of cast aluminum parts. The results show that the DiaForce® thin film sensor retain maintain their sensory function in spite of contact with 700 °C temperature molten aluminium. Thus, it offers a novel approach for series manufacturing of castings with embedded sensory function for health monitoring and detection of mechanical overcharge is established.