Hong Wang

Fatigue responses of lead zirconate titanate stacks under semibipolar electric cycling with mechanical preload

Lead zirconate titanate (PZT) stacks that had an interdigital internal electrode configuration were tested to more than 108 cycles. A 100 Hz semibipolar sine wave with a field range of +4.5/−0.9 kV/mm was used in cycling with a concurrently-applied 20 MPa preload. Significant reductions in piezoelectric and dielectric responses were observed during the cycling depending on the measuring condition. Extensive partial discharges were also observed. These surface events resulted in the erosion of external electrode and the exposure of internal electrodes. Sections prepared by sequential polishing technique revealed a variety of damage mechanisms including delaminations, pores, and etch grooves. The scale of damage was correlated with the degree of fatigue-induced reduction in piezoelectric and dielectric responses. The results from this study demonstrate the feasibility of using a semibipolar mode to drive a PZT stack under a mechanical preload and illustrate the potential fatigue and damages of the stack in ...

Fatigue response of a PZT multilayer actuator under high-field electric cycling with mechanical preload

An electric fatigue test system was developed for evaluating the reliability of piezoelectric actuators with a mechanical loading capability. Fatigue responses of a lead zirconate titanate (PZT) multilayer actuator with a platethrough electrode configuration were studied under an electric field (1.7 times that of the coercive field of PZT material) and a concurrent mechanical preload (30.0 MPa). A total of 109 cycles was carried out. Variations in charge density and mechanical strain under the high electric field and constant mechanical loads were observed during the fatigue test. The dc and the first harmonic (at 10 Hz) dielectric and piezoelectric coefficients were subsequently characterized using fast Fourier transformation. Both the dielectric and the piezoelectric coefficients exhibited a monotonic decrease prior to 2.86×108 cycles under certain preloading conditions, and then fluctuated. Both the dielectric loss tangent and the piezoelectric loss tangent also fluctuated after a decrease. The results...

Effects of electric field and biaxial flexure on the failure of poled lead zirconate titanate

Reliable design of lead zirconate titanate (PZT) piezo stack actuators demands that several issues, including electromechanical coupling and ceramic strength-size scaling, be scrutinized. This study addresses those through the use of ball-on-ring (BoR) biaxial flexure strength tests of a PZT piezoelectric material that is concurrently subjected to an electric field. The Weibull strength distributions and fracture surfaces were examined. The mechanical failures were further analyzed in terms of internal stress, energy release rate, and domain-switching toughening. Both the sign and the magnitude of an electric field had a significant effect on the strength of poled PZT within the tested range. A surface flaw type with an average depth of around 18 mum was identified to be the strength limiter and responsible for the failure of the tested PZT under both mechanical and electromechanical loadings. With a value of 0.74 MPamiddotm1/2 in the absence of electric field, the fracture toughness of the poled PZT was affected by an applied electric field just as the strength was affected. These results and observations have the potential to serve probabilistic reliability analysis and design optimization of multilayer PZT piezo actuators.

Fatigue of extracted lead zirconate titanate multilayer actuators under unipolar high field electric cycling

Testing of large prototype lead zirconate titanate (PZT) stacks presents substantial technical challenges to electronic testing systems, so an alternative approach that uses subunits extracted from prototypes has been pursued. Extracted 10-layer and 20-layer plate specimens were subjected to an electric cycle test under an electric field of 3.0/0.0 kV/mm, 100 Hz to 108 cycles. The effects of measurement field level and stack size (number of PZT layers) on the fatigue responses of piezoelectric and dielectric coefficients were observed. On-line monitoring permitted examination of the fatigue response of the PZT stacks. The fatigue rate (based on on-line monitoring) and the fatigue index (based on the conductance spectrum from impedance measurement or small signal measurement) were developed to quantify the fatigue status of the PZT stacks. The controlling fatigue mechanism was analyzed against the fatigue observations. The data presented can serve as input to design optimization of PZT stacks and to operat...

Progress Letter Report on Bending Fatigue Test System Development for Spent Nuclear Fuel Vibration Integrity Study (Out-of-cell fatigue testing development - Task 2.4)

Vibration integrity of high burn-up spent nuclear fuel in transportation remains to be a critical component of US nuclear waste management system. The structural evaluation of package for spent fuel transportation eventually will need to see if the content or spent fuel is in a subcritical condition. However, a system for testing and characterizing such spent fuel is still lacking mainly due to the complication involved with dealing radioactive specimens in a hot cell environment. Apparently, the current state-of-the-art in spent fuel research and development is quite far away from the delivery of reliable mechanical property data for the assessment of spent fuels in the transport package evaluation. Under the sponsorship of US NRC, ORNL has taken the challenge in developing a robust testing system for spent fuel in hot cell. An extensive literature survey was carried out and unique requirements of such testing system were identified. The U-frame setup has come to the top among various designs examined for reverse bending fatigue test of spent fuel rod. The U-frame has many features that deserve mentioned here: Easy to install spent fuel rod in test; Less linkages than in conventional bending test setup such as three-point or four-point bending; Target the failure mode relevant to the fracture of spent fuel rod in transportation by focusing on pure bending; The continuous calibrations and modifications resulted in the third generation (3G) U-frame testing setup. Rigid arms are split along the LBB axis at rod sample ends. For each arm, this results in a large arm body and an end piece. Mating halves of bushings were modified into two V-shaped surfaces on which linear roller bearings (LRB) are embedded. The rod specimen is installed into the test fixture through opening and closing slide end-pieces. The 3G apparently has addressed major issues of setup identified in the previous stage and been proven to be eligible to be further pursued in this project. On the other hand, the purchase of universal testing machine or Bose dual LM2 TB was completed and the testing system was delivered to ORNL in August 2012. The preliminary confirmation of the system and on-site training were given by Bose field engineer and regional manager on 8/1-8/2/2012. The calibration of Bose testing system has been performed by ORNL because the integration of ORNL setup into the Bose TestBench occurred after the installation. Major challenge with this process arose from two aspects: 1) the load control involves two load cells, and 2) U-frame setup itself is a non-standard specimen. ORNL has been able to implement the load control through Cycle Indirect along with pinning the U-frame setup. Two meetings with ORNL hot-cell group (November 2012 and January 2013) were held to discuss the potential issues with both epoxy mounting of rigid sleeve and U-frame setup. Many suggestions were provided to make the procedure friendlier to the manipulator in hot cell. Addressing of these suggestions resulted in another cycle of modifications of both vise mold and setup. The initial meeting with ORNL I&C group occurred in November 2012 with regard to the Bose cable modification and design of central panel to integrate the cables and wires. The first round of cable modification and central panel fabrication was completed in February 2012. The testing with the modified cables exhibited substantial noises and the testing system was not shown to be stable. It was believed the cross talk was responsible to the noise, and a central panel with a better grounding and shielding was highly recommended. The central panel has been re-designed and fabricated in March 2013. In the subsequent period, the ORNL made substantial effort to debug the noises with the load cell channel, and to resolve the noises and nonlinearity with RDP LVDTs related to the integration of RDP LVDTs to Bose system. At the same time, ORNL has completed the verification tests of Bose test system, including cycle tests under reversal bending in load control, bending tests under monotonic load, and cycle tests under reversal bending in load control on MTS machine to verify the results of Bose machine. These results are shown to be consistent under equivalent loading conditions, especially for the cycle tests. Rad hardened LVDTs will be incorporated into the Bose system once received, and 10 Hz tests will be completed in the next step. The schedule for the final check of the Bose system is being finalized before the system delivered to the hot cell.

Specific Energy and Scratch Hardness of Gamma Titanium Aluminides Subjected to Single-Grit Pendulum Scratching

Two gamma titanium aluminides (Daido RNT650 and HOWMET 45XD) with fully lamellar structure but with different colony sizes were studied using a single-grit pendulum (rotational) scratch tester in order to assess their abrasive wear resistances. The maximum depth of groove was ∼ 0.07 mm and the scratch velocity used was ∼ 1 m/s. Normal and tangential forces were monitored during each scratch. The material removal mechanisms were examined using a scanning electron microscope (SEM) and also measured using a laser profilometer. Extensive thermal softening was observed. Sizable fractures were revealed in the transverse direction; however, the role of these fractures in the chip formation depends on the microstructure of materials and the size of groove. The tribological properties were characterized by instantaneous specific energy and scratch hardness as related to the depth of the groove. The overall response of materials can be effectively characterized by the HEM (Hwang-Evans-Malkin) model and the PSR (proportional specimen resistance) model, even though the underlining material removal might be subjected to the different mechanisms. The TiAl with the larger colony or grain size exhibits a strong resistance to material loss or material removal (higher depth-independent specific energy) while exhibiting lower scratch hardness. The obtained depth-independent specific energy and scratch hardness can be used to screen the candidate materials depending on whether the application is sliding or impact dominant.Copyright

Structural health monitoring of compression connectors for overhead transmission lines

Two-stage aluminum conductor steel-reinforced (ACSR) compression connectors are extensively used in US overhead transmission lines. The connectors are made by crimping a steel sleeve onto a steel core and an aluminum sleeve over electrical conducting aluminum strands. The connectors are designed to operate at temperatures up to 125°C, but their performance is increasingly degrading because of overloading of lines. Currently, electric utilities conduct routine line inspections using thermal and electrical measurements, but these methods do not provide information about the structural integrity of connectors. In this work, structural health monitoring (SHM) of compression connectors was studied using electromechanical impedance (EMI) analysis. Lead zirconate titanate (PZT)-5A was identified as a smart material for SHM. A flexible high-temperature bonding layer was used to address challenges in PZT integration due to a significant difference in the coefficients of thermal expansion of PZT and the aluminum substrate. The steel joint on the steel core was investigated because it is responsible for the ultimate tensile strength of the connector. Tensile testing was used to induce structural damage to the joint, or steel core pullout, and thermal cycling introduced additional structural perturbations. EMI measurements were conducted between the tests. The root mean square deviation (RMSD) of EMI was identified as a damage index. The use of steel joints has been shown to enable SHM under simulated conditions. The EMI signature is sensitive to variations in structural conditions. RMSD can be correlated to the structural health of a connector and has potential for use in the SHM and structural integrity evaluation.

Performance of PZT stacks under high-field electric cycling at various temperatures in heavy-duty diesel engine fuel injectors

Testing and characterization of large prototype lead zirconate titanate (PZT) stacks present substantial technical challenges to electronic systems. The work in this study shows that an alternative approach can be pursued by using subunits extracted from prototype stacks. Piezoelectric and dielectric integrity was maintained even though the PZT plate specimens experienced an additional loading process involved with the extraction after factory poling. Extracted 10-layer plate specimens were studied by an electric cycle test under an electric field of 3.0/0.0 kV/mm, 100 Hz to 108 cycles, both at room temperature (22°C) and at 50°C. The elevated temperature had a defined impact on the fatigue of PZT stacks. About 48 and 28% reductions were observed in the piezoelectric and dielectric coefficients, respectively, after 108 cycles at 50°C, compared with reductions of 25 and 15% in the respective coefficients at 22°C. At the same time, the loss tangent varied to a limited extent. The evolution of PZT–electrode interfacial layers or nearby dielectric layers should account for the difference in the fatigue rates of piezoelectric and dielectric coefficients. But the basic contribution to observed fatigue may result from the buildup of a bias field that finally suppressed the motion of the domain walls. Finally, monitoring of dielectric coefficients can be an effective tool for on-line lifetime prediction of PZT stacks in service if a failure criterion is defined properly.

Material Removal and Specific Energy in the Dynamic Scratching of Gamma Titanium Aluminides

Mechanical responses of three gamma titanium aluminides (TiAls) (denoted as Alloy A, Alloy B and Alloy C) subjected to dynamic scratching were studied by using a single-grit pendulum (rotating) scratch tester. The maximum depth of groove was {approx} 0.07 mm, and the scratch velocity was {approx} 1.0 m/s. Normal and tangential forces were monitored. The material removal mechanisms were examined using a scanning electron microscope (SEM) and the scratches were measured by using a laser profilometer. The mechanical properties of the tested TiAls were characterized by the instantaneous specific energy, scratch resistance and scratch hardness as related to the groove depth. Extensive thermal softening was observed in the dynamic scratch test of the TiAls, which facilitated both the detachment of developing chips and pile-up of material on side ridges. Sizable fractures were observed in the transverse direction in the tested TiAls; these fractures tended to participate in the chip formation, depending on the microstructure of the TiAl and the size of the scratch groove. Specific energy and scratch hardness are depth-dependent to various degrees for the TiAls tested. The material removal might be subjected to different mechanisms, but the overall material response can be effectively characterized by the HEM (Hwang, Evans and Malkin) model and the PSR (proportional specimen resistance) model. The depth-independent specific energy and scratch hardness can be used to screen candidate materials for the applications that are scratch-dominated versus impact-dominated. Among the three tested TiAls, the TiAl with larger colony or grain size exhibits a stronger capability of energy dissipation during material removal (higher depth-independent specific energy), while the TiAl with smaller colony size shows a higher resistance to indentation (higher depth-independent scratch hardness). The observations and conclusions in this study can serve as a base line for the further characterization of the related materials under the service temperature as recommended for diesel engine.