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Assembly of smart adaptronic piezo-metal composites by use of prefabricated batches of piezoceramic micro parts

: Neugebauer, Reimund; Koriath, Hans-Joachim; Müller, Michael


Lynch, J.P. ; Society of Photo-Optical Instrumentation Engineers -SPIE-, Bellingham/Wash.:
Sensors and Smart Structures Technologies for Civil, Mechanical, and Aerospace Systems 2013 : 10 March 2013, San Diego, California
Bellingham, WA: SPIE, 2013 (Proceedings of SPIE 8692)
ISBN: 978-0-8194-9475-7
Paper 869224
Conference "Sensors and Smart Structures Technologies for Civil, Mechanical, and Aerospace Systems" <2013, San Diego/Calif.>
Fraunhofer IWU ()
composite; electrode; metal; sensor; tolerancing

Current technologies for smart sheet metal part production base upon adhesive bonding of piezo-patches to the surface. A novel concept and process chain is the assembly of piezoceramic micro parts into local microstructures of metal sheets and subsequent joining by forming. This results in a full functional integration of the piezoceramic in the metal for sensor and actuator purposes. Mechanical coupling is non-positive without elastic interlayers and the electrical coupling is characterized by the metal being the ground electrode of the sensor. The paper describes the design, methods and tolerance management to overcome the challenges for reliable parallel microassembly and joining of prefabricated batches of 10 piezoceramic fibers with dimensions of 0.267 × 0.250 × 10 mm3 and nominal assembly clearances of ±0.018 mm. The prefabrication of the batches is achieved by stacking and dicing of piezoceramic plates. Both the principles of precision machining and elastic averaging are applied for reliable production and joining of the batches. In experiments, equally spaced piezoceramic fibers within the batches were achieved. Prototypes were assembled and joined by forming achieving functional piezo-metal composites. With the given tolerances of the parts and the microstructure a statistical tolerance analysis has been performed in order to determine the maximum allowable position uncertainty of the microassembly system. An assembly yield of > 95% is expected for future scaled up high volume assembly of piezo-metal composites.