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DFG CRC/Transregio 39 PT-PIESA
Project Areas

Project Areas

Research focus in the project areas and in the individual subprojects

A short summary is featured below presenting the fundamental content regarding the individual project areas and subprojects.

 

 

The Project Area A focuses within the third founding period on increasing the productivity and process reliability during the production of sensor-actuator-modules. The primary focus of the research is the setting defined module´s characteristics in order to enable application-optimized structure functions after the component integration in Project Area B.

 

SP A01:Manufacturing Technologies of Functional Piezoelectric Components for Integration into Lightweight Structures:

Aim of the project is the design, construction and characterization of functional piezoelectric components on the basis of piezo ceramic-polymer-composite and LTC/PZT modules, which will be available to the process chain. The main emphasis here is setting of defined properties for the compliance of specific application structure functions. This shall be achieved by a careful selection and layout of the components, as well as the structured deposition of electrodes.

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Subproject Manager:
Prof. Alexander Michaelis
Institution: Technische Universität Dresden
Dr. Sylvia Gebhardt
Institution: Fraunhofer-Institiut für Keramische Technologien uns Systeme IKTS

 

TP A02: Micro Structuring and Joining Processes for Integration Piezo Fiber Batches in Metallic Structures:

This subproject deals with the micro structuring of cavities and the joining processes for integration piezo fiber batches in metallic structures. Thereby the research work is focused on the process reliability and productivity´s increase of the micro structuring process. Through internal process control of the joining process a defined pretension of the direct integrated piezo-fibers should be achieved.

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Subproject Manager:
Prof. Andreas Schubert
Institution: Technische Universität Chemnitz
Dr. Hans-Joachim Koriath
Institution: Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU

 

SP A03: Thin Layer Technology for Metal Based Piezoelectric Modules:

In the second founding period was successful demonstrated the electromechanical coupling of composites from piezo-fibers (piezo fiber batches) in sheet metal and micro injection components. A production-ready complete technology for the Piezo-Fiber-Batches production should be developed, since these through an application-specific construction enable the performance of different structure functions.

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Subproject Manager:
Dr. Siegfried Peter
Institution: Technische Universität Chemnitz
Dr. Volker Wittstock
Institution: Technische Universität Chemnitz

 

SP A04: Laser-Based Electric-Contacting Method for Composite Components with Integrated Active Elements:

The contacting and insulation of the contact point is relevant for all chain processes. For this purpose the reproducibility and robustness of the nozzle system technology for the bazing alloy joints are further increase. Furthermore a fully integrable procedure for the local applications of thermoplastics through spray on and laser beam melting will be explored.

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Subproject Manager:
Dr. Stephan Roth
Institution: Bayerisches Laserzentrum GmbH
Prof. Michael Schmidt
Institution: Friedrich-Alexander Universität Erlangen-Nürnberg

 

SP A05: Development of a Thermoplastic Composite Compatible Piezo-Ceramic Module and its Related Manufacturing Process:

The goal is the methodical development and technological implementation of thermoplastic-composite compatible piezo ceramic-modules, whose thermoplastic foils are already coordinated with the matrix material of the thermoplastic composite structure. The emphasis on the third founding period is on the electrodes and contacting strategies, the process chain´s general expansion of the TCPM application areas through the TCPM- materials portfolio, as well as the anisotropy-based module pre-stressing.

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Subproject Manager:
Prof. Maik Gude
Institution: Technische Universität Dresden

 

TP A06:Production Technologies for Piezo Modules with Integrated Ceramic Composites and Functional Polymers for the Employment in Active Metallic Components:

Based on the industrial-scale capable two component-injection molding technology, micro structured piezoelectric semi-finished products should be electrically contacted and insulated, so that the piezoelectric modules with completed packaging arise with optimized execution. In addition, new thermoplastic piezo compound should be developed and through injection molding processed.

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Subproject Manager:
Prof. Lothar Kroll
Institution: Technische Universität Chemnitz
Dr. Jürgen Tröltzsch
Institution: Technische Universität Chemnitz

 

 

The Project Area B focuses within the third founding period on the technological development for the production of thin walled lightweight structures with defined multifunctionality. In terms of the series production capacity, productivity process and reliability for the technologies will be pursued, also for extensive and complex three-dimensional curved component structures.

 

SP B01: Shaping of Piezo-Metal-Compounds and Numerical Studies of Forming and Functionality:


In the production of Piezo-Metal-Compounds through adhesive with floating storage and technological forming joining should further increased the reproducibility and productivity by means of an automated application of adhesive and piezo modules , as well as the selective spatially hardening process of adhesive. The numerical simulation of the forming and joining process and the composite´s functionality provides as a result an essential contribution to the process reliability.

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Subproject Manager:
Prof. Welf-Guntram Drossel
Institution: Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU
Dr. Roland Müller
Institution: Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU

 

SP B03:  Integration of Piezo Ceramic Modules in Aluminium Castings Using High Pressure Die Casting – Technology Development and Numerical Process Simulation


The increase of the robustness of the method for the complete integration of piezo ceramic sensor-actuator modules pressure-cast aluminium components and the functionality´s improvement are the research priorities for the subproject during the third founding period. The process development supported by a numerical simulation of the highly dynamic procedures during the pressure-cast aluminium process.

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Subproject Manager:
Prof. Carolin Körner
Institution: Friedrich-Alexander-Universität Erlangen-Nürnberg

 

SP B04: Robust Manufacturing Technologies for Fiber-Reinforced Thermoplastic Composite Components with Integrated Piezo-Ceramic-Modules:


The procedure for integration of fiber-reinforced thermoplastic piezo modules will be within the third founding period transferred to additional application-related reinforcing materials and matrix-material systems. Particular focus is placed on the expansion of the manufacturing complex in order to develop a new customized tempering-transfer system, as well as the illustration of the multiple curved shapes and the integration of evaluation electronic in generic demonstrator structures.

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Subproject Manager:
Prof. Niels Modler
Institution: Technische Universität Dresden

 

SP B06: Industrial-Scale Production Technologies for Glass Fiber-Polyurethane Composite Structures with Integrated Piezo Ceramic Sensor Elements and Adjusted Evaluation Electronic:

 

Aim of the subproject is the production of active component structures of glass fiber-polyurethane composites through direct integration, bonding and polarization of piezo-fibers/beads. Furthermore the subproject is developing during, the third founding period, a production-ready circuit carriers and hybrid technologies for the electronic integration, particularly control and evaluation electronics, information processing and wireless communication.

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Subproject Manager:
Prof. Maik Gude
Institution: Technische Universität Dresden
Prof. Wolf-Joachim Fischer
Institution: Technische Universität Dresden

 

 

The Project Area C is focused within the third founding period on the interpretation and non-destructive examinations of adaptive composites. Within the project area, a solid foundation is created for the optimal application-oriented interpretation of complex composite structures and the quality assurance in large scale applications. The non-destructive examinations and the development of a suitable test methodology for complex formed composite components gains particularly importance, since a characterization with known procedures and methods could be possible only with large scale unportrayable effort, due to the multi curved structures.

 

SP C03: Design of Poling Technology for Series Production for Manufacturing of Adaptive Components of Structures:


The introduction of a permanent polarization as an essential process step for the activation of the electromechanical coupling in functional composites is the main subject of the research work within the third founding period. On the basis of material characterization sampling and polarity simulations a polarity process optimization is derived, methods on polarity of unstructured composite materials are developed, also damage mechanism and critical areas are identified.

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Subproject Manager:
Dr. Peter Neumeister
Institution: Fraunhofer-Institiut für Keramische Technologien und Systeme IKTS
Dr. Andreas Schönecker
Institution: Fraunhofer-Institiut für Keramische Technologien und Systeme IKTS

 

SP C06: Material Characterization and Numerical Simulation for Adaptive Material Compounds:


Precise material parameters for the interpretation of adaptive composites can be gained through an inverse methods and iterative comparison with simulation models. In addition, within the third founding period should result a simulation platform for the numerical calculation of the entire system behavior of adaptive material systems as basis for the module positioning in composites.

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Subproject Manager:
Prof. Reinhard Lerch
Institution: Friedrich-Alexander-Universität Erlangen-Nürnberg
Dr. Stefan Johann Rupitsch
Institution: Friedrich Alexander-Universität Erlangen-Nürnberg

 

SP C07: Curing and Shrinking Processes Simulation of Joining Materials in Non-Malleable Piezo Metal Composites:


The aim of the sub project in the third founding period is the continuous thermos-mechanically coupled simulation and experimental characterization for the description of the gluing process during the sheet metal forming with floating stored piezo modules. In the process should be lastly developed a spatial and temporal temperature profiles for the industrialization process.

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Subproject Manager:
Prof. Jörn Ihlemann
Institution: Technische Universität Chemnitz

 

SP C08: Polarization Determination of Integrated Piezo-Ceramic for Process Control and Non-Destructive Component Testing:

The laser intensity modulation method (LIMM), as a non-destructive testing method, enables the determination of the polarization condition of integrated piezo ceramics, as well as the embedding´s quality. The overcoming of limitations regarding penetration depth in conductive lightweight structures through the application pulsed laser with elevated thermal capacity is the aim of the third founding period.

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Subproject Manager:
Prof. Gerald Gerlach
Institution: Technische Universtität Dresden

 

SP C09: Model-Based Ultrasound Imaging for Spatially Resolved Flaw Detection in Layered Composites:

The new submitted sub project was focuses within the third founding period on the ultrasonic dimensional defect detection in adaptive material compounds. The physical processes in the media boundaries of the composite materials are being taken into consideration through a synthetic focusing method, thereby achieving an optimal lateral local resolution. Thus, a dimensional registration of unwanted defects in thin-walled and curved components is possible.

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Subproject Manager:
Dr. Stefan Johann Rupitsch
Institution: Friedrich-Alexander-Universtität Erlangen-Nürnberg

 

 

The Transfer Projects create the transition of technologies towards production oriented industrial applications.

 

TP T01: TP T01: Integration of Piezo-Modules in Structural Components of an Automobile´s Rear Axle for Active Vibration Compensation and Gear Noise Reduction:

In vehicles with rear and 4-wheel drive can arise disturbing sounds that are transmitted to the passenger compartment resulting from vibrations in the rear axle. The new submitted project has as main aim to introduce the piezo actuators direct in the component in the production process of the rear axle components (e.g. rear axle subframe) in order to achieve the aspired vibration control, on the basis on the technology developed by the CRR/ TR 39 on piezo-metal composites.

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Subproject Manager:
Prof. Welf-Guntram Drossel
Institution: Frauenhofer-Institiut für Werkzeugmachschinen und Umformtechnik IWU

 

TP T02:Plastic-Based Integration Piezo-Ceramic Functionalized Carrier Materials in Components for Large-Scale Production:


The junction of the technology approach between plastic based forming of metallic or fiber-reinforced plastic (FRP) depositors and the embedding of sensors in the component to be shaped is to be achieved by the integration of metal or organic sheets with applied sensoric functional elements through injection molding. With this, complex application and assembly steps of sensor systems in hybrid structures are omitted. Central questions arise from the depositor´s forming procedure, as well as the sensitive embedding procedures.

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Subproject Manager:
Prof. Lothar Kroll
Institution: Technische Universität Chemnitz

 

TP T03: Design and Manufacturing of Fiber-Reinforced Structures with Integrated Actuator-Sensor-Arrays for Technical Measurement Applications:

The main objective of this submitted transfer project is the manufacture of fiber-reinforced structures with material integrated actuator-sensor- arrays. Hereby, a contribution is to be made towards industrial-scale implementation of function-integrated structures. Possible applications for such wAS-Arrays include, for example, diagnostic systems of security-related components with supporting function e.g. for automobiles, wind turbine, air ducts or intake systems with higher functional integration in the form of integrated flow rate and temperature measurement or structures with sensoric additional functions such as fenders with integrated distance-measurement system.

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Subproject Manager:
Prof. Niels Modler
Institution: Technische Universität Dresden
Dr. Martin Dannemann
Institution: Technische Universität Dresden

 

CP K2: Investigation of Functionality Potential through Piezo-Module-Integration in 3D Structures:

Within the context of the Collaborative Research Center /Transregio 30 (PT-PIESA) high-volume production compatible product technologies for diverse piezo ceramic composites will be analyzed. These mass-produced peizoceramic composites with integration in 3D structures offer a great potential in terms of application and functionality. According to the double layers composite, which are produced through fixing flat piezo actuators between the sheet metals during the forming process, the potentials of these piezo metal multilayer composite should be sound for active vibration and acoustic noise influence.

The influence of the layer structure, the piezo actuators positioning within the layer structure, in the in-plane and within the forming area of the double layered composite, as well as the exploited piezo effect (d31/d33 or d15) should be experimentally and simulative analyzed for possible vibration influence efficiency. The basis of the simulations model builds a description of the state space for piezo-mechanical systems built on previous projects with the intention that it should be expanded towards the acoustic. Within the project a series of statements are expected, which determine the frequency range´s geometry and material parameters, where a modal influence of the sound radiation energetic effective possible is.



Subproject Manager:
Prof. Welf-Guntram Drossel
Institution: Technische Universität Chemnitz

 

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