Darren J. Hartl

Aerospace applications of shape memory alloys

Abstract With the increased emphasis on both reliability and multi-functionality in the aerospace industry, active materials are fast becoming an enabling technology capturing the attention of an increasing number of engineers and scientists worldwide. This article reviews the class of active materials known as shape memory alloys (SMAs), especially as used in aerospace applications. To begin, a general overview of SMAs is provided. Their useful properties and engineering effects are described and the methods in which these may be utilized are discussed. A review of past and present aerospace applications is presented. The discussion addresses applications for both atmospheric earth flight as well as space flight. To complete the discussion, SMA design challenges and methodologies are addressed and the future of the field is examined.

Origami-inspired active structures: a synthesis and review

Origami, the ancient art of paper folding, has inspired the design of engineering devices and structures for decades. The underlying principles of origami are very general, which has led to applications ranging from cardboard containers to deployable space structures. More recently, researchers have become interested in the use of active materials (i.e., those that convert various forms of energy into mechanical work) to effect the desired folding behavior. When used in a suitable geometry, active materials allow engineers to create self-folding structures. Such structures are capable of performing folding and/or unfolding operations without being kinematically manipulated by external forces or moments. This is advantageous for many applications including space systems, underwater robotics, small scale devices, and self-assembling systems. This article is a survey and analysis of prior work on active self-folding structures as well as methods and tools available for the design of folding structures in general and self-folding structures in particular. The goal is to provide researchers and practitioners with a systematic view of the state-of-the-art in this important and evolving area. Unifying structural principles for active self-folding structures are identified and used as a basis for a quantitative and qualitative comparison of numerous classes of active materials. Design considerations specific to folded structures are examined, including the issues of crease pattern identification and fold kinematics. Although few tools have been created with active materials in mind, many of them are useful in the overall design process for active self-folding structures. Finally, the article concludes with a discussion of open questions for the field of origami-inspired engineering.

Use of a Ni60Ti shape memory alloy for active jet engine chevron application: II. Experimentally validated numerical analysis

A shape memory alloy (SMA) composition of Ni60Ti40 (wt%) was chosen for the fabrication of active beam components used as cyclic actuators and incorporated into morphing aerospace structures. The active structure is a variable-geometry chevron (VGC) designed to reduce jet engine noise in the take-off flight regime while maintaining efficiency in the cruise regime. This two-part work addresses the training, characterization and derived material properties of the new nickel-rich NiTi composition, the assessment of the actuation properties of the active beam actuator and the accurate analysis of the VGC and its subcomponents using a model calibrated from the material characterization. The second part of this two-part work focuses on the numerical modeling of the jet engine chevron application, where the end goal is the accurate prediction of the VGC actuation response. A three-dimensional (3D) thermomechanical constitutive model is used for the analysis and is calibrated using the axial testing results from part I. To best capture the material response, features of several SMA constitutive models proposed in the literature are combined to form a new model that accounts for two material behaviors not previously addressed simultaneously. These are the variation in the generated maximum actuation strain with applied stress level and a smooth strain–temperature constitutive response at the beginning and end of transformation. The accuracy of the modeling effort is assessed by comparing the analysis deflection predictions for a given loading path imposed on the VGC or its subcomponents to independently obtained experimental results consisting of photogrammetric data. For the case of full actuation of the assembled VGC, the average error in predicted centerline deflection is less than 6%.

Use of a Ni60Ti shape memory alloy for active jet engine chevron application: I. Thermomechanical characterization

A shape memory alloy (SMA) with a composition of Ni60Ti40 (wt%) was chosen for the fabrication of active beam elements intended for use as cyclic actuators and incorporated into a morphing aerospace structure. The active structure is a variable-geometry chevron (VGC) designed to reduce jet engine noise in the take-off flight regime while maintaining efficiency in the cruise regime. This two-part work addresses the training, characterization and derived material properties of the new nickel-rich composition, the assessment of the actuation properties of the active beam actuator and the accurate analysis of the VGC and its subcomponents using a model calibrated from the material characterization. The characterization performed in part I of this work was intended to provide quantitative information used to predict the response of SMA beam actuators of the same composition and with the same heat treatment history. Material in the form of plates was received and ASTM standard tensile testing coupons were fabricated and tested. To fully characterize the material response as an actuator, various thermomechanical experiments were performed. Properties such as actuation strain and transformation temperatures as a function of applied stress were of primary interest. Results from differential scanning calorimetry, monotonic tensile loading and constant stress thermal loading for the as-received, untrained material are first presented. These show lower transformation temperatures, higher elastic stiffnesses (60–90 GPa) and lower recoverable transformation strains (≈1.5%) when compared to equiatomic NiTi (Nitinol). Stabilization (training) cycles were applied to the tensile specimens and characterization tests were repeated for the stable (trained) material. The effects of specimen training included the saturation of cyclically generated irrecoverable plastic strains and a broadening of the thermal transformation hysteresis. A set of final derived material properties for this stable material is provided. Finally, the actuation response of a structural beam component composed of the same material given the same thermomechanical processing conditions was assessed by applying a constant bias load and a variable bias load as thermal actuation cycles were imposed.

Constitutive modeling and structural analysis considering simultaneous phase transformation and plastic yield in shape memory alloys

The new developments summarized in this work represent both theoretical and experimental investigations of the effects of plastic strain generation in shape memory alloys (SMAs). Based on the results of SMA experimental characterization described in the literature and additional testing described in this work, a new 3D constitutive model is proposed. This phenomenological model captures both the conventional shape memory effects of pseudoelasticity and thermal strain recovery, and additionally considers the initiation and evolution of plastic strains. The model is numerically implemented in a finite element framework using a return mapping algorithm to solve the constitutive equations at each material point. This combination of theory and implementation is unique in its ability to capture the simultaneous evolution of recoverable transformation strains and irrecoverable plastic strains. The consideration of isotropic and kinematic plastic hardening allows the derivation of a theoretical framework capturing the interactions between irrecoverable plastic strain and recoverable strain due to martensitic transformation. Further, the numerical integration of the constitutive equations is formulated such that objectivity is maintained for SMA structures undergoing moderate strains and large displacements. The implemented model has been used to perform 3D analysis of SMA structural components under uniaxial and bending loads, including a case of local buckling behavior. Experimentally validated results considering simultaneous transformation and plasticity in a bending member are provided, illustrating the predictive accuracy of the model and its implementation.

Advanced methods for the analysis, design, and optimization of SMA-based aerostructures

Engineers continue to apply shape memory alloys to aerospace actuation applications due to their high energy density, robust solid-state actuation, and silent and shock-free operation. Past design and development of such actuators relied on experimental trial and error and empirically derived graphical methods. Over the last two decades, however, it has been repeatedly demonstrated that existing SMA constitutive models can capture stabilized SMA transformation behaviors with sufficient accuracy. This work builds upon past successes and suggests a general framework by which predictive tools can be used to assess the responses of many possible design configurations in an automated fashion. By applying methods of design optimization, it is shown that the integrated implementation of appropriate analysis tools can guide engineers and designers to the best design configurations. A general design optimization framework is proposed for the consideration of any SMA component or assembly of such components that applies when the set of design variables includes many members. This is accomplished by relying on commercially available software and utilizing tools already well established in the design optimization community. Such tools are combined with finite element analysis (FEA) packages that consider a multitude of structural effects. The foundation of this work is a three-dimensional thermomechanical constitutive model for SMAs applicable for arbitrarily shaped bodies. A reduced-order implementation also allows computationally efficient analysis of structural components such as wires, rods, beams and shells. The use of multiple optimization schemes, the consideration of assembled components, and the accuracy of the implemented constitutive model in full and reduced-order forms are all demonstrated.

Design optimization and uncertainty analysis of SMA morphing structures

The continuing implementation of shape memory alloys (SMAs) as lightweight solid-state actuators in morphing structures has now motivated research into finding optimized designs for use in aerospace control systems. This work proposes methods that use iterative analysis techniques to determine optimized designs for morphing aerostructures and consider the impact of uncertainty in model variables on the solution. A combination of commercially available and custom coded tools is utilized. ModelCenter, a suite of optimization algorithms and simulation process management tools, is coupled with the Abaqus finite element analysis suite and a custom SMA constitutive model to assess morphing structure designs in an automated fashion. The chosen case study involves determining the optimized configuration of a morphing aerostructure assembly that includes SMA flexures. This is accomplished by altering design inputs representing the placement of active components to minimize a specified cost function. An uncertainty analysis is also conducted using design of experiment methods to determine the sensitivity of the solution to a set of uncertainty variables. This second study demonstrates the effective use of Monte Carlo techniques to simulate the variance of model variables representing the inherent uncertainty in component fabrication processes. This paper outlines the modeling tools used to execute each case study, details the procedures for constructing the optimization problem and uncertainty analysis, and highlights the results from both studies.

Design and Optimization of a Shape Memory Alloy-Based Self-Folding Sheet

Origami engineering—the practice of creating useful three-dimensional structures through folding and fold-like operations on two-dimensional building-blocks—has the potential to impact several areas of design and manufacturing. In this article, we study a new concept for a self-folding system. It consists of an active, self-morphing laminate that includes two meshes of thermally-actuated shape memory alloy (SMA) wire separated by a compliant passive layer. The goal of this article is to analyze the folding behavior and examine key engineering tradeoffs associated with the proposed system. We consider the impact of several design variables including mesh wire thickness, mesh wire spacing, thickness of the insulating elastomer layer, and heating power. Response parameters of interest include effective folding angle, maximum von Mises stress in the SMA, maximum temperature in the SMA, maximum temperature in the elastomer, and radius of curvature at the fold line. We identify an optimized physical realization for maximizing folding capability under mechanical and thermal failure constraints. Furthermore, we conclude that the proposed self-folding system is capable of achieving folds of significant magnitude (as measured by the effective folding angle) as required to create useful 3D structures.

SMI 2013: Towards building smart self-folding structures

We report our initial progress on synthesizing complex structures from programmable self-folding active materials, which we call Smart Multi-Use Reconfigurable Forms. We have developed a method to unfold a given convex polygonal mesh into a one-piece planar surface. We analyze the behavior of this surface as if it were constructed from realistic active materials such as shape memory alloys (SMAs), in which sharp creases and folds are not feasible. These active materials can change their shapes when they are heated and have been applied to medical, aerospace, and automotive applications in the engineering realm. We demonstrate via material constitutive modeling and utilization of finite element analysis (FEA) that by appropriately heating the unfolded planar surface it is possible to recover the 3D shape of the original polygonal mesh. We have simulated the process and our finite element analysis simulations demonstrate that these active materials can be raised against gravity, formed, and reconfigured automatically in three dimensions with appropriate heating in a manner that extends previous work in the area of programmable matter. Based on our results, we believe that it is possible to use active materials to develop reprogrammable self-folding complex structures.

Characterization and 3-D modeling of Ni60Ti SMA for actuation of a variable geometry jet engine chevron

This work describes the thermomechanical characterization and FEA modeling of commercial jet engine chevrons incorporating active Shape Memory Alloy (SMA) beam components. The reduction of community noise at airports generated during aircraft take-off has become a major research goal. Serrated aerodynamic devices along the trailing edge of a jet engine primary and secondary exhaust nozzle, known as chevrons, have been shown to greatly reduce jet noise by encouraging advantageous mixing of the streams. To achieve the noise reduction, the secondary exhaust nozzle chevrons are typically immersed into the fan flow which results in drag, or thrust losses during cruise. SMA materials have been applied to this problem of jet engine noise. Active chevrons, utilizing SMA components, have been developed and tested to create maximum deflection during takeoff and landing while minimizing deflection into the flow during the remainder of flight, increasing efficiency. Boeing has flight tested one Variable Geometry Chevron (VGC) system which includes active SMA beams encased in a composite structure with a complex 3-D configuration. The SMA beams, when activated, induce the necessary bending forces on the chevron structure to deflect it into the fan flow and reduce noise. The SMA composition chosen for the fabrication of these beams is a Ni60Ti40 (wt%) alloy. In order to calibrate the material parameters of the constitutive SMA model, various thermomechanical experiments are performed on trained (stabilized) standard SMA tensile specimens. Primary among these tests are thermal cycles at various constant stress levels. Material properties for the shape memory alloy components are derived from this tensile experimentation. Using this data, a 3-D FEA implementation of a phenomenological SMA model is calibrated and used to analyze the response of the chevron. The primary focus of this work is the full 3-D modeling of the active chevron system behavior by considering the SMA beams as fastened to the elastic chevron structure. Experimental and numerical results are compared. Discussion is focused on actuation properties such as tip deflection and chevron bending profile. The model proves to be an accurate tool for predicting the mechanical response of such a system subject to defined thermal inputs.