Post on 29-Dec-2019
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Printed strain gauges for aircraft load detection using Aerosol Jet® printing Aerosol Jet® User Group Meeting
Dipl.-Ing. Elmar Taubenrauch / Dr. Ingo Wirth
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Printed strain gauges for aircraft load detection using Aerosol Jet® printing
Introduction Fraunhofer IFAM
INKtelligent printing® at Fraunhofer IFAM
Aerosol Jet® printing in EU-Project CLEAN SKY
INKtelligent® printer at Fraunhofer IFAM
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
IntroductionFraunhofer-Institute for Manufacturing Technology and Advanced Materials - IFAM
Departments Shaping and Functional
Materials Adhesive Bonding
Technology and Surfaces
Locations in Bremen andDresden
Project groups in Oldenburgand Stade
478 employees
Overall budget 2010:35.3 million €
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
IntroductionPrinting activites at Fraunhofer IFAM
Business Areas Competencies
Automotive / Aerospace Process and Material Development /Functional Integration
Microsystems / Electronic Industry
Sensor Systems
Energy Management Energy Harvesting
Medical Engineering / Nano Technology
Medical Diagnostics / Nanoparticle Systems
Manufacturing Systems Engineering
Shaping and ProductionTechnologies
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Design & Layout
Material screening
Printing process
Characterisation
Ink formulation
INKtelligent printing®
Technology platform
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
INKtelligent printing®
Deposition technologies at Fraunhofer IFAM
Screen printing
Ink-Jet-printing: Dimatix, Voxeljet, Microdrop
Aerosol Jet®, INKtelligent® printer
Dispensing machine for high viscous composites
Rapid Manufacturing: 3D printing, selective laser sintering
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
INKtelligent printing®
Application areas
Automotive
Aerospace
Robot technology
Medical Technology
Microsystem Technology
Electronic Industry
Sensor Technology
Medical Diagnostics
Solar Technology
Functionalized Textiles and Composites
Miniaturization and Integration
New deposition materials
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
IFAM activities in Clean Sky using Aerosol Jet® printing technology
Development of load sensors to support active load control
Clean Sky is the largest European aeronautical research programme(~ 1.6 billion €) devoted to environment and places Europe at theforefront of the greening of aviation
Clean Sky - Structural Health Monitoring (SHM)Load sensor evaluation
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Clean Sky - Structural Health Monitoring (SHM)Motivation
© C. Bockenheimer, Airbus Deutschland GmbH: SMIST – Structural Monitoring with Advanced Integrated Sensor Technologies – Aeronautic Days, Vienna, 19.-21.06.2006
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Design of strain gauges on Aircraft wing
Objective: Optimal Signal-Noise-Ratio
Product / Process:
Load Control
Signal Factor:Piezo–resistive effect
Control Factor:e.g. position, material, …
Noise Factor:e.g. temperature influence, …
Response:Change in el. resistivity
Clean Sky - Structural Health Monitoring (SHM)Motivation
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
FE-Analysis
Calculation of dislocation function and strain components:
Optimal position and orientation for strain gauge
Dislocation function
Mechanical forces (uplift)
Strain in z direction
Clean Sky - Structural Health Monitoring (SHM)Robust Design
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Sensor material requirements based on strain demands
FE stress analysis: strain gauges under mechanical load: Pt - material
FE stress analysis: strain gauges under mechanical load: Ag - material
Clean Sky - Structural Health Monitoring (SHM)Robust Design
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Wheatstone full bridge
strain gauge printed on substratewhich is fixed in a tensile tester
resistance Rx = additional resistancefor bridge balancing
measuring setup parameters:
room temperature tensile and compressive stress testing frequency 25 Hz 105 cycles
Clean Sky - Structural Health Monitoring (SHM)Aerosol Jet® printed strain gauges
5 mm5 mm
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Sensor test equipment
dynamic measure-ments up to 50 Hz
maximum stress~ 20 kN
Clean Sky - Structural Health Monitoring (SHM)Sensor evaluation
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Measurement setup
Clean Sky - Structural Health Monitoring (SHM)Sensor evaluation
printed silver strain gauge
temperature compensation
VISHAYfoil strain gauge (reference)
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Clean Sky - Structural Health Monitoring (SHM)
test no sensor material / substrate
tensile stress μstrain [μm/m]
compressive stress μstrain [μm/m]
cycles frequency
1 Ag on Al 50 50 1.000 25 Hz
2 Ag on Al 250 125 1.000 25 Hz
3 Ag on Al 550 125 1.000 25 Hz
4 Ag on Al 1.100 125 1.000 25 Hz
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Clean Sky - Structural Health Monitoring (SHM)test no sensor material /
substratetensile stress μstrain [μm/m]
compressive stress μstrain [μm/m]
cycles frequency
5 Ag on Al 1.100 125 5.000.000 25 Hz
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Clean Sky - Structural Health Monitoring (SHM)
test no sensor material / substrate
tensile stress μstrain [μm/m]
compressive stress μstrain [μm/m]
cycles frequency
6 Ag on Al 1.100 125 100.000 25 Hz
constant signal of printed Ag strain gauges → no cracks inprintedstructure
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Clean Sky - Structural Health Monitoring (SHM)Printing of Ag strain gauges on Al specimen
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Clean Sky - Structural Health Monitoring (SHM)Printed Ag strain gauges on Al specimen
Oven sintering of printed strain gauges on Al specimen
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Time dependence of electrical resistance during oven sintering process at T = 120 °C
Clean Sky - Structural Health Monitoring (SHM)Printed strain gauges on Al specimen
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Clean Sky - Structural Health Monitoring (SHM)Printed Ag strain gauges on Al specimen
Printed strain gauges with temperature compensation
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Aerosol printed strain gauges for active load control
Development of Ag, Cu/Ni and other nanodispersed inks
Application of printed strain gauges on several parts and differentsurfaces
Development and investigation for sensorial applications
Clean Sky - Structural Health Monitoring (SHM)Sensor evaluation
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM – Functional StructuresINKtelligent® Printer
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® PrinterMotivation and requirementsVariable substrate sizes
Prototyping with original customer parts orcomplete assemblies
Substrate height ≥ 200mm
max. substrate width 450mm
Variability in fixing or clamping thecomponents on the machine table
Possibility of inline-production, goodaccessibility
Usage of specific work piece carriers
Automatic substrate feeding by an industryroboter planned
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® PrinterMotivationFull functionality in 3D-Printing
printing on curved surfaces or on differentplanes with different printing methods
exact measuring of customer parts with newgeometry
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® Printer
mechanical base – small CNC milling machine
high mechanical flexibility
enabling technology for many rapid prototypingmethods
sufficient accuracy and good stiffness in all axes
variable software and controlling system
easy to use
economical design
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® Printer
mechanical base – small CNC milling machine
IFAM INKtelligent® Printer - Technical Data
stepper motors (X/Y/Z) 4A 300Ncm
repeat accuracy ≤ 15μm
max. failure in positioning ≤ 8μm
axis length (X/Y/Z) 850mm / 450mm / 270mm
guidings ball screw / ball rail systems in all axis
machine table size 1350mm x 640mm
maximal component height 280mm
linear resolution (X/Y/Z) 3,125μm
max. movement speed (X/Y/Z) 60mm/s
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® Printer
Aerosol headfixing port Shutter
Pneumatic Cylinder
Process View Camera
Measuring Sensor
Optomec Aerosol Jet® - standard printing head
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® Printer
Aerosol headfixing port Shutter
Pneumatic Cylinder
Process View Camera
Measuring Sensor
Optomec Aerosol Jet® - standard printing head
same nozzle position for different print-heads
process view camera
fixed shutter
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® Printer
Optomec Aerosol Jet® - standard printing head
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® Printer
Optomec Aerosol Jet® - standard printing head
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® Printer
Aerosol Jet® - Closely coupled print head assembly (CCPA)
water cooled thermal isolation bracket
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® Printer
Optomec Aerosol Jet® - Printing on 3D-Surfaces
measuring sensor, fixed on a separate Z-support
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® Printer
other functions: dispensing with rotary valve
volumetric extrusion of highly viscous materialby a disposable feed screw, easy to change/clean
motor
materialdepot
spindle
nozzle
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® Printer
other functions: spraying-valve
homogeneous spaying jet for surface coating
material ‐depot
spray jet
needle
compressed air
piston
spring
compressed air
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® Printer
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Fraunhofer IFAM - Functional StructuresINKtelligent® Printer
© Fraunhofer IFAMContact: Dr. Ingo Wirth, Tel.: +49 421-2246-232 Dipl.-Ing. Elmar Taubenrauch, Tel.: -113ingo.wirth@ifam.fraunhofer.de elmar.taubenrauch@ifam.fraunhofer.de
Aerosol Jet® printing at Fraunhofer IFAMInterdisziplinary team
Prof. Dr.-Ing. Matthias Busse
Cindy Behrens
Ass. Andreas Burblies
Dr.-Ing. Dirk Godlinski
Dipl.-Ing. Arne Haberkorn
Dr. Róbert Kun
Dr.-Ing. Dirk Lehmhus
Dipl.-Ing. Marcus Maiwald
Dr. Edit Kunné Pál
Dipl.-Mat. Natalia Reichert
Tim Rusch
Dipl.-Ing. Torben Seemann
Dipl.-Ing. Elmar Taubenrauch
Dr. Ingo Wirth
Dipl.-Ing. Christian Werner
Gert-M. Wöbken
Dr. Volker Zöllmer
Thank youfor your attention!