The integration of piezoceramic based sensors and actuators offers a possibility to produce multifunctional materials
with enhanced properties. Die casting is an innovative approach for the fabrication of metal matrix smart structural
components where the functional module is totally integrated in the interior of the cast part. A technique to support and
protect the sensitive sensor/actuator-modules in the die during the highly dynamic die filling process is presented.
Demonstration parts were produced which are fully capable to be activated to vibrate. An approach to characterize in
detail the behavior of the sensor/actuator-module after the integration in the cast matrix is presented. Both FE
computation and electric impedance measurements are used to quantify how the casting process affects the performance
of the integrated sensor/actuator-modules.
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