Functionalisation of PM components by integration of inherent data carriers and sensory elements

Apart from a great variety of shaping possibilities powder metallurgical techniques offer the integration of foreign elements for static and variable data storage or to embed elements with sensory features in structural parts. The integration of foreign elements as single parts arranged in matrices or traces of foreign powders allows for storing information like brand, serial numbers or other codable data. Integrated sensor elements can be utilised for monitoring loading conditions like strains and stresses or temperatures during the life-cycle of technical parts. In this work foreign elements were embedded in the powder prior to consolidation. The powder was compacted to a green body and sintered afterwards. During compaction the foreign elements interact with the base material and change their position according to the deformation of the surrounding powder. Finite element analyses were carried out in order to detect a suitable initial arrangement of foreign elements and to ensure their correct position at the end of compaction. Furthermore, the interface conditions between the base powder and the foreign elements are of interest. Therefore experimental investigations were carried out using magneto elastic sensors consisting of NiFe-layers on different substrates as aluminium, silicium and aluminium oxide with aluminium and steel powder. The bonding quality was analysed by metallographic investigations. By means of X-ray and Computed Tomography (CT) the position of the foreign elements within the parts is controlled, which is of a high importance for a correct determination of loading conditions and to read out stored information.