Method for Large‐Scale Production of Piezoceramic‐Metal‐Compounds

The integration of sensors and actuators in material‐compounds allows for additional functionalities within minimum space. Especially, piezoelectric materials are widely used in industrial applications, such as fuel injection or positioning. Up to now, production of sheet‐metal‐compounds with a sensor and actuator functionality is strongly restricted by manual fabrication processes. The design of a material‐compound including aluminum sheet metals and flat piezoceramic fibers (piezoceramic‐metal‐compound) and a process chain allowing for an automated production offers the possibility of serial production. The compound design, the process chain for the fabrication of semi‐finished parts, the forming into structural parts, and the functionality are presented. The process chain enables piezoceramic‐metal‐compounds for large‐scale production. Piezoceramic‐metal‐compounds are used as sensors and actuators. The authors propose a forming process chain that provides semi‐finished parts with integrated piezomodules to shorten cycle times. Furthermore, an adhesive is utilized that partly remains in a liquid condition when forming takes place. A proper temperature–time regime is identified. Finally, the forming limits of the process are investigated.