Christopher L. Bertagne

Analysis of Highly Coupled Thermal-Structural Responses in Morphing Radiative Bodies

As the field of smart structures matures, a variety of active components are being explored. One example is a morphing radiator that uses shape memory alloys (SMAs) to actuate, thereby altering its geometric effectiveness. This device exhibits a high degree of thermomechanical coupling due to the active response of the shape memory alloy and the radiative heat transfer taking place on the surface of the radiator assembly. This paper presents and demonstrates a multiphysical finite element analysis-based framework capable of simulating general problems of this type. The framework decomposes the coupled behavior of the radiator into two separate but interacting analyses: one representing the structural response and one representing the thermal solution. Two example problems are provided in order to demonstrate the flexibility of the framework. Additionally, a reduced-order mathematical model is developed for one of the problems.

Simulating coupled thermal-mechanical interactions in morphing radiators

Thermal control is an important aspect of every spacecraft. The thermal control system (TCS) must maintain the temperature of all other systems within acceptable limits in spite of changes in environmental conditions or heat loads. Most thermal control systems used in crewed vehicles use a two-fluid-loop architecture in order to achieve the flexibility demanded by the mission. The two-loop architecture provides sufficient performance, but it does so at the cost of additional mass. A recently-proposed radiator concept known as a morphing radiator employs shape memory alloys in order to achieve the performance necessary to use a single-loop TCS architecture. However, modeling the behavior of morphing radiators is challenging due to the presence of a unique and complex thermomechanical coupling. In this work, a partitioned analysis procedure is implemented with existing finite element solvers in order to explore the behavior of a possible shape memory alloy-based morphing radiator in a mission-like thermal environment. The results help confirm the theory of operation and demonstrate the ability of this method to support the design and development of future morphing radiators.

Design and Fabrication of a Composite Morphing Radiator Panel Using High Conductivity Fibers

Upcoming crewed space missions will involve large internal and external heat loads and require advanced thermal control systems to maintain a desired internal environment temperature. Radiators with at least 12:1 turndown ratios (the ratio between the maximum and minimum heat rejection rates) will be needed. However, current technologies are only able to achieve turndown ratios of approximately 3:1. A morphing radiator capable of altering shape could significantly increase turndown capabilities. Shape memory alloys offer qualities that may be well suited for this endeavor; their temperature-dependent phase changes could offer radiators the ability to passively control heat rejection. In 2015, a morphing radiator prototype was constructed and tested in a thermal vacuum environment, where it successfully demonstrated the morphing behavior and variable heat rejection. Newer composite prototypes have since been designed and manufactured using two distinct types of SMA materials. These models underwent temperature cycling tests in a thermal vacuum chamber and a series of fatigue tests to characterize the lifespan of these designs. The focus of this paper is to present the design approach and testing of the morphing composite facesheet. The discussion includes: an overall description of the project background, definition of performance requirements, composite materials selection, use of analytic and numerical design tools, facesheet fabrication, and finally fatigue testing with accompanying results.

Feedback Control Applied to Finite Element Models of Morphing Structures

This paper demonstrates a framework for integrating full feedback control with a high-fidelity finite element model in order to simulate control of morphing structures. Most of the previous finite element simulations involving control of morphing structures consider the effects of the controller, but do not incorporate true feedback control. Additionally, when feedback control is considered, numerical models other than finite element analysis are used. Thus, a trade-off must be made between a high-fidelity model and consideration of feedback control. In this work, these aspects are unified to create a tool that can simulate real-time feedback control of a finite element model.The framework itself consists of two components: the finite element model and the controller. The finite element model must be capable of varying external loads as the solution evolves in time. In this paper, the finite element model is implemented in ABAQUS. The controller component is written in Python. In order to ensure the framework is suitable for a wide range of applications, no assumptions are made regarding the natures of the finite element model or the control architecture. Additionally, the components are designed to be modular. For example, simulating different controller architectures does not require alteration of the finite element model. The result is a highly flexible framework that is particularly well-suited for validating and demonstrating controllers on high-fidelity models.© 2014 ASME

Towards experimental validation of an analysis framework for morphing radiators

Thermal control is an important aspect of spacecraft design, particularly in the case of crewed vehicles, which must maintain a precise internal temperature at all times in spite of sometimes drastic variations in the external thermal environment and internal heat loads. The successes of the Space Shuttle and International Space Station programs have shown that this can be accomplished in Low Earth Orbit (LEO), however, crewed spacecraft traveling beyond LEO are expected to encounter more challenging thermal conditions with significant variations in both the heat rejection requirements and environment temperature. Such missions will require radiator systems with high turndown ratios, defined as the ratio between the maximum and minimum heat rejection rates achievable by the radiator system. Current radiators are only able to achieve turndown ratios of 3:1, far less than the 12:1 turndown ratio which is expected to be required on future missions. An innovative radiator concept, known as a morphing radiator, uses the temperature-induced shape change of shape memory alloy (SMA) materials to achieve a turndown ratio of at least 12:1. Predicting the thermal and structural behavior of SMA-based morphing radiators is challenging due to the presence of two-way thermomechanical coupling that has not been widely considered in the literature. Previous work has demonstrated the application of a technique known as a partitioned analysis procedure which can be used to simulate the behavior of morphing radiators. This work describes ongoing efforts to evaluate the physical accuracy of this approach by conducting validation studies. A detailed finite element model of a morphing radiator is developed and executed using the framework. Preliminary results show close agreement between the experimental data and model predictions, giving additional confidence in the partitioned approach.

Aero−structural Optimization of Shape Memory Alloy-based Wing Morphing via a Class/Shape Transformation Approach

Because of the continuous variability of the ambient environment, all aircraft would benefit from an in situ optimized wing. This paper proposes a method for preliminary design of feasible morphing wing configurations that provide benefits under disparate flight conditions but are also each structurally attainable via localized active shape change operations. The controlled reconfiguration is accomplished in a novel manner through the use of shape memory alloy embedded skin components. To address this coupled optimization problem, multiple sub-optimizations are required. In this work, the optimized cruise and landing airfoil configurations are determined in addition to the shape memory alloy actuator configuration required to morph between the two. Thus, three chained optimization problems are addressed via a common genetic algorithm. Each analysis-driven optimization considers the effects of both the deformable structure and the aerodynamic loading experienced by the wing. Aerodynamic considerations are addressed via a two-dimensional panel method and each airfoil shape is generated by the so-called class/shape transformation methodology. It is shown that structurally and aerodynamically feasible morphing of a modern high-performance sailplane wing produces a 22% decrease in weight and significantly increases stall angle of attack and lift at the same landing velocity when compared to a baseline design that employs traditional control surfaces.

Development and Testing of a Shape Memory Alloy-Driven Composite Morphing Radiator

Future crewed deep space missions will require thermal control systems that can accommodate larger fluctuations in temperature and heat rejection loads than current designs. To maintain the crew cabin at habitable temperatures throughout the entire mission profile, radiators will be required to exhibit turndown ratios (defined as the ratio between the maximum and minimum heat rejection rates) as high as 12:1. Potential solutions to increase radiator turndown ratios include designs that vary the heat rejection rate by changing shape, hence changing the rate of radiation to space. Shape memory alloys exhibit thermally driven phase transformations and thus can be used for both the control and actuation of such a morphing radiator with a single active structural component that transduces thermal energy into motion. This work focuses on designing a high-performance composite radiator panel and investigating the behavior of various SMA actuators in this application. Three designs were fabricated and subsequently tested in a relevant thermal vacuum environment; all three exhibited repeatable morphing behavior, and it is shown through validated computational analysis that the morphing radiator concept can achieve a turndown ratio of 27:1 with a number of simple configuration changes.