Manufacturing Technologies of Piezoelectric Components for Integration into Lightweight Structures

Piezoelectric sensors and actuators have gained increasing interest in lightweight engineering for shape control, vibration damping, condition, and structural health monitoring. In combination with complementary control units, these adaptive structures become more relevant as cost‐effective technologies and mass production of suitable piezoelectric components are available. The authors investigate serial and cost‐effective fabrication of piezoceramic components and composites, which allow for direct integration into lightweight structures. To succeed functional integration, layout, structure, and composition of the piezoelectric components need to be adjusted to the lightweight material and to the constraints of the entire manufacturing process. Examples of robust piezoelectric components for integration into fiber‐reinforced plastics and light metal parts are given. Manufacturing, properties, and influence of structure integration on physical characteristics are described and discussed in detail. Novel piezoceramic components are investigated which can be directly integrated into lightweight materials to build smart structures and systems. Layout, configuration, and composition of the piezoelectric components are specifically adjusted to the constraints of the entire manufacturing process succeeding functional integration. Piezoceramic fibers, fragments, pearls, and piezocomposites thereof are especially suited for integration into fiber‐reinforced plastics. LTCC/piezoceramic modules can be embedded into die casted aluminum parts, sustaining enormous temperature and pressure changes during process. Details on manufacture and material parameters are presented.