Abstract
While in general manufacturing and functional integration are separated steps, in this article a continuous mass-production enabled procedure is discussed. The essential component of the manufactured laminate is a functionalised thermoplastic film that is combined with piezoceramic powder (lead zirconate titanate - PZT) and carbon nanotubes (CNT). The challenge is to achieve optimal electrical and electromechanical properties and a good processability while simultaneously preserving the high toughness of the composite and the required adhesive strength with the joined metal sheet. Determining the optimal joining and surface treatment parameters by identifying the interlaminar shear strength between the metal and plastic components allows for a continuous rolling production process with a subsequent roll forming process. Further investigations on the forming properties are concerned with the optimal placement of the sensors as well as the arrangement and shape of the electrodes. A neural network approach is evaluated to facilitate detection and localisation of external forces in order to use such functional hybrid laminates for new operating concepts in the interior of motor vehicles or for structural health monitoring.
Highlights
Introduction and motivationThe research and development of technologies for the production of complex plastic/metal-based composite components have been the subject of intense scientific and application-oriented efforts for many years
The essential component of the manufactured laminate is a functionalised thermoplastic film that is combined with piezoceramic powder and carbon nanotubes (CNT)
To embed such systems in hybrid laminates, semi-finished sheet products are joined with electromechanical functionalised polymer films by combining the extrusion technology with the metalworking rolling technology
Summary
The research and development of technologies for the production of complex plastic/metal-based composite components have been the subject of intense scientific and application-oriented efforts for many years. The plastics processing extrusion technology allows for an efficient roll to roll production of microelectromechanical systems (MEMS) To embed such systems in hybrid laminates, semi-finished sheet products are joined with electromechanical functionalised polymer films by combining the extrusion technology with the metalworking rolling technology. Process costs, "smart" hybrid structures can be manufactured more economically and with more energy efficiency, compared to classical sequential technologies This method allows the first large-scale in-line production of a PZT-based transducer system without the use of energyintensive sintering processes. The combination of a process chain suitable for mass production, structural components with integrated sensors and an intelligent evaluation system provides the possibility to develop new smart materials whose manufacturing and functionalisation are adaptive to new structural geometries and application scenarios. Energy efficient manufacturing by merging several different production processes and using their residual heat
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