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Integrating Electronic Components, Sensors and Actuators in Cast Metal Components: An Overview of the State of the Art

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Advances in System-Integrated Intelligence (SYSINT 2022)

Part of the book series: Lecture Notes in Networks and Systems ((LNNS,volume 546))

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Abstract

Despite the fact that specifically in the automotive industry, several safety-relevant components are produced by casting processes, integrating sensors and electronic components in castings has so far received less attention than the production of smart, self-monitoring components made e.g. from fibre-reinforced plastics (FRP), or by means of additive manufacturing techniques. One reason for this apparent scarcity are the harsh conditions to be endured by integrated systems in processes that rely on processing large amounts of metal in the liquid state. Despite such obstacles, a deeper scrutiny of the topic reveals several studies which solve the underlying problem in quite different ways and in view of different application scenarios such as part identification, load monitoring, damage detection or structural health monitoring. The latter aspect, which has received considerable attention in the aerospace industry in the past, is starting to find interest in the automotive sector, too. A major motivation behind this paradigm shift are autonomous drive and car sharing scenarios, which effectively detach the individual driver from its role in observing the state of the vehicle. The present article summarizes the state of the art in the field, discussing potential applications of smart castings, looking at the various casting processes from lost foam, sand and gravity die casting to low and high pressure die casting, as well as looking at the different sensor and electronic systems being studied in this context.

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Author information

Authors and Affiliations

  1. Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM), Wiener Straße 12, 28359, Bremen, Germany

    Dirk Lehmhus, Thomas Rahn, Christoph Pille & Matthias Busse

Authors
  1. Dirk Lehmhus
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  2. Thomas Rahn
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  3. Christoph Pille
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  4. Matthias Busse
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Corresponding author

Correspondence to Dirk Lehmhus .

Editor information

Editors and Affiliations

  1. Department of Electrical, Electronic and Telecommunication Engineering and Naval Architecture (DITEN), University of Genova, Genoa, Italy

    Maurizio Valle

  2. Fraunhofer Institute for Manufacturing Technology and Advanced Materials, Bremen, Germany

    Dirk Lehmhus

  3. Department of Electrical, Electronic and Telecommunication Engineering and Naval Architecture (DITEN), University of Genova, Genoa, Italy

    Christian Gianoglio

  4. Department of Electrical, Electronic and Telecommunication Engineering and Naval Architecture (DITEN), University of Genova, Genoa, Italy

    Edoardo Ragusa

  5. Department of Electrical, Electronic and Telecommunication Engineering and Naval Architecture (DITEN), University of Genova, Genoa, Italy

    Lucia Seminara

  6. Computer Science and Mathematics, University of Bremen, Bremen, Germany

    Stefan Bosse

  7. Department of Electrical and Electronics Engineering (EEE), Lebanese International University (LIU), Beirut, Lebanon

    Ali Ibrahim

  8. BIBA, University of Bremen, Bremen, Germany

    Klaus-Dieter Thoben

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Lehmhus, D., Rahn, T., Pille, C., Busse, M. (2023). Integrating Electronic Components, Sensors and Actuators in Cast Metal Components: An Overview of the State of the Art. In: Valle, M., et al. Advances in System-Integrated Intelligence. SYSINT 2022. Lecture Notes in Networks and Systems, vol 546. Springer, Cham. https://doi.org/10.1007/978-3-031-16281-7_34

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  • DOI: https://doi.org/10.1007/978-3-031-16281-7_34

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