Encapsulating Piezoresistive Thin Film Sensors Based on Amorphous Diamond-Like Carbon in Aluminium Castings

The paper describes a new approach for the in-process integration of sensors into lightweight metal components made of aluminium and fabricated by casting. It examines the suitability of DiaForce thin film sensors based on piezoresistive hydrocarbon layers (DLC) for integration in molten aluminium. In contrast to previous research, a technology is introduced which will allow real-time measurement of both dynamic and static loads for the detection of permanent deformation of cast aluminum parts. The results show that the DiaForce thin film sensors maintain their sensory function in spite of contact with molten aluminium at a temperature of 700 °C. Thus a novel approach for series production of castings with embedded sensory function for health monitoring and detection of mechanical overcharge is established.