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Thermomechanical Response of Shape Memory Alloy Hybrid Composites

This study examines the use of embedded shape memory alloy (SMA) actuators for adaptive control of the thermomechanical response of composite structures. A nonlinear thermomechanical model is presented for analyzing shape memory alloy hybrid composite (SMAHC) structures exposed to steady-state thermal and dynamic mechanical loads. Also presented are (1) fabrication procedures for SMAHC specimens, (2) characterization of the constituent materials for model quantification, (3) development of the test apparatus for conducting static and dynamic experiments on specimens with and without SMA, (4) discussion of the experimental results, and (5) validation of the analytical and numerical tools developed in the study. Excellent agreement is achieved between the predicted and measured SAMHC responses including thermal buckling, thermal post-buckling and dynamic response due to inertial loading. The validated model and thermomechanical analysis tools are used to demonstrate a variety of static and dynamic response behaviors including control of static (thermal buckling and post-buckling) and dynamic responses (vibration, sonic fatigue, and acoustic transmission). and SMAHC design considerations for these applications. SMAHCs are shown to have significant advantages over conventional response abatement approaches for vibration, sonic fatigue, and noise control.

Turner, Travis L.

Compositionally-Graded Shape Memory Film for Self-Deployment of Membrane Reflectors and Optics

The next generation of space systems will require large apertures in order to image faint targets or cover large areas of Earth. These large apertures must be able to fit inside a launch vehicle fairing, be light enough for launch into orbit, and deploy on orbit with repeatability and reliability. The current state-of-the-art in flight optics is represented by the 4 meter LAMP telescope, with an areal density of 10 km sq m. Development of a Beryllium mirror demonstration article for NGST (Next Generation Space Telescope) at the University of Arizona indicate areal densities of 0.5 kg sq m with flight hardware in the 12 meter range. With progressive improvements in existing deployment, packaging, and structural technologies, the size of optics and reflectors will continue to increase, while mass is reduced. However, without a breakthrough in materials, packaging and/or deployment technologies, the goal for Gossamer structures of 0.1 kg sq m is unachievable for the near and mid-term NASA missions. Membrane technology provides the best hope of achieving such low areal densities. In combination with advances in membrane materials and structures, development of revolutionary techniques for deployment systems can provide significant improvements in large aperture technology. In this paper, the results of a six-month Phase I research effort to demonstrate the application of thin film NiTi to aerospace-qualified membrane and mesh materials are presented. Deposition of shape memory thin film was achieved Astromesh (trademark) metal mesh and CP-1, and optical-quality polymer membrane. Not only was full-coating deposition demonstrated, but also small segment deposition which holds potential for local surface control. Deployment of these materials was also demonstrated, setting the stage for the development of a larger test article.

Hill, Lisa

Structural Acoustic Response of Shape Memory Alloy Hybrid Composite Panels

A method has been developed to predict the structural acoustic response of shape memory alloy hybrid composite panels subjected to acoustic excitation. The panel is modeled by a finite element analysis and the radiated field is predicted using Rayleigh's integral. Transmission loss predictions for the case of an aluminum panel excited by a harmonic acoustic pressure are shown to compare very well with a classical analysis. Predictions of the normal velocity response and transmitted acoustic pressure for a clamped aluminum panel show excellent agreement with experimental measurements. Predicted transmission loss performance for a composite panel with and without shape memory alloy reinforcement are also presented. The preliminary results demonstrate that the transmission loss can be significantly increased with shape memory alloy reinforcement.

Turner, Travis L.

Functionally Graded Metal-Metal Composite Structures

Methods and devices are disclosed for creating a multiple alloy composite structure by forming a three-dimensional arrangement of a first alloy composition in which the three-dimensional arrangement has a substantially open and continuous porosity. The three-dimensional arrangement of the first alloy composition is infused with at least a second alloy composition, where the second alloy composition comprises a shape memory alloy. The three-dimensional arrangement is consolidated into a fully dense solid structure, and the original shape of the second alloy composition is set for reversible transformation. Strain is applied to the fully dense solid structure, which is treated with heat so that the shape memory alloy composition becomes memory activated to recover the original shape. An interwoven composite of the first alloy composition and the memory-activated second alloy composition is thereby formed in the multiple alloy composite structure.

Brice, Craig A.

Segmented, Pleat-Folded and Rib-Supported Thin-Shell Composite Antenna Reflector

A new architecture scalable to sizes greater than 10 m for a deployable solid surface reflector antenna is presented. The design makes use of radially and circumferentially segmented thin-shell composite gores interconnected on the back side by a series of flexible shape memory composite elements. The reflector surface stows like an umbrella by creating serpentine-shaped pleats in the thin shell while being supported by a simple-hinged metering rib structure. A parametric study assessed how design features affect the deployed stiffness of the reflector and are used to identify a test matrix for manufacturing, foldability, and shape accuracy assessments. Various manufacturing tooling designs and dedicated folding fixtures were built to increase the fidelity and confidence of the test articles produced. An overview of the development effort is provided.

Deployable antennas

Segmented, Pleat-Folded and Rib-Supported Thin-Shell Composite Antenna Reflector

A new architecture scalable to sizes greater than 10 m for a deployable solid surface reflector antenna is presented. The design makes use of radially and circumferentially segmented thin-shell composite gores interconnected on the back side by a series of flexible shape memory composite elements. The reflector surface stows like an umbrella by creating serpentine-shaped pleats in the thin shell while being supported by a simple-hinged metering rib structure. A parametric study assessed how design features affect the deployed stiffness of the reflector and are used to identify a test matrix for manufacturing, foldability, and shape accuracy assessments. Various manufacturing tooling designs and dedicated folding fixtures were built to increase the fidelity and confidence of the test articles produced. An overview of the development effort is provided.

Deployable antennas

Measurement and Prediction of the Thermomechanical Response of Shape Memory Alloy Hybrid Composite Beams

Previous work at NASA Langley Research Center (LaRC) involved fabrication and testing of composite beams with embedded, pre-strained shape memory alloy (SMA) ribbons within the beam structures. That study also provided comparison of experimental results with numerical predictions from a research code making use of a new thermoelastic model for shape memory alloy hybrid composite (SMAHC) structures. The previous work showed qualitative validation of the numerical model. However, deficiencies in the experimental-numerical correlation were noted and hypotheses for the discrepancies were given for further investigation. The goal of this work is to refine the experimental measurement and numerical modeling approaches in order to better understand the discrepancies, improve the correlation between prediction and measurement, and provide rigorous quantitative validation of the numerical analysis/design tool. The experimental investigation is refined by a more thorough test procedure and incorporation of higher fidelity measurements such as infrared thermography and projection moire interferometry. The numerical results are produced by a recently commercialized version of the constitutive model as implemented in ABAQUS and are refined by incorporation of additional measured parameters such as geometric imperfection. Thermal buckling, post-buckling, and random responses to thermal and inertial (base acceleration) loads are studied. The results demonstrate the effectiveness of SMAHC structures in controlling static and dynamic responses by adaptive stiffening. Excellent agreement is achieved between the predicted and measured results of the static and dynamic thermomechanical response, thereby providing quantitative validation of the numerical tool.

Davis, Brian

Investigation of the Thermomechanical Response of Shape Memory Alloy Hybrid Composite Beams

Previous work at NASA Langley Research Center (LaRC) involved fabrication and testing of composite beams with embedded, pre-strained shape memory alloy (SMA) ribbons. That study also provided comparison of experimental results with numerical predictions from a research code making use of a new thermoelastic model for shape memory alloy hybrid composite (SMAHC) structures. The previous work showed qualitative validation of the numerical model. However, deficiencies in the experimental-numerical correlation were noted and hypotheses for the discrepancies were given for further investigation. The goal of this work is to refine the experimental measurement and numerical modeling approaches in order to better understand the discrepancies, improve the correlation between prediction and measurement, and provide rigorous quantitative validation of the numerical model. Thermal buckling, post-buckling, and random responses to thermal and inertial (base acceleration) loads are studied. Excellent agreement is achieved between the predicted and measured results, thereby quantitatively validating the numerical tool.

Davis, Brian A.

Structural Acoustic Response of a Shape Memory Alloy Hybrid Composite Panel (Lessons Learned)

This study presents results from an effort to fabricate a shape memory alloy hybrid composite (SMAHC) panel specimen and test the structure for dynamic response and noise transmission characteristics under the action of thermal and random acoustic loads. A method for fabricating a SMAHC laminate with bi-directional SMA reinforcement is described. Glass-epoxy unidirectional prepreg tape and Nitinol ribbon comprise the material system. Thermal activation of the Nitinol actuators was achieved through resistive heating. The experimental hardware required for mechanical support of the panel/actuators and for establishing convenient electrical connectivity to the actuators is presented. Other experimental apparatus necessary for controlling the panel temperature and acquiring structural acoustic data are also described. Deficiency in the thermal control system was discovered in the process of performing the elevated temperature tests. Discussion of the experimental results focuses on determining the causes for the deficiency and establishing means for rectifying the problem.

Turner, Travis L.

Measurement and Prediction of the Thermomechanical Response of Shape Memory Alloy Hybrid Composite Beams

An experimental and numerical investigation into the static and dynamic responses of shape memory alloy hybrid composite (SMAHC) beams is performed to provide quantitative validation of a recently commercialized numerical analysis/design tool for SMAHC structures. The SMAHC beam specimens consist of a composite matrix with embedded pre-strained SMA actuators, which act against the mechanical boundaries of the structure when thermally activated to adaptively stiffen the structure. Numerical results are produced from the numerical model as implemented into the commercial finite element code ABAQUS. A rigorous experimental investigation is undertaken to acquire high fidelity measurements including infrared thermography and projection moire interferometry for full-field temperature and displacement measurements, respectively. High fidelity numerical results are also obtained from the numerical model and include measured parameters, such as geometric imperfection and thermal load. Excellent agreement is achieved between the predicted and measured results of the static and dynamic thermomechanical response, thereby providing quantitative validation of the numerical tool.

Davis, Brian

Initial Results of the MISSE-Flight Facility Polymers and Composites Experiment 1-4 (PCE 1-4)

Spacecraft in low Earth orbit (LEO) are subjected to harsh environmental conditions, including radiation (cosmic rays, ultraviolet (UV), x-ray and charged particle radiation), micrometeoroids and orbital debris, temperature extremes, thermal cycling, and atomic oxygen (AO). These environmental exposures can result in erosion, embrittlement and optical property degradation of susceptible materials threatening spacecraft performance and durability. To increase our understanding of effects such as AO erosion and radiation induced embrittlement of spacecraft materials, NASA Glenn Research Center has developed a series of experiments that are flown as part of the Materials International Space Station Experiment (MISSE) missions on the exterior of the International Space Station (ISS). These experiments have provided critical space environmental durability data such as AO erosion data of polymers and composites, and radiation induced mechanical property degradation of spacecraft insulation materials, after long term space exposure. In continuing these studies, four Glenn experiments with 365 flight samples have been flown on ISS’s external MISSE-Flight Facility (MISSE-FF). These experiments are the Polymers and Composites Experiment-1 (PCE-1) flown as part of the inaugural MISSE-9 mission, the PCE-2 flown as part of the MISSE-10 mission, the PCE-3 flown as part of the MISSE-12 and MISSE-15 missions, and the PCE-4 flown as part of the MISSE-13 mission. The primary objective of the PCE 1-4 experiments is to determine the AO and radiation durability of spacecraft polymers and composites. In addition, each experiment has a wide variety of spacecraft materials and hence they each have numerous additional sample objectives. Each of the PCE 1-4 is designed to examine the consequences of AO interactions including AO erosion yield (Ey) and optical and thermal property characterization. Several polymers were flown in both ram and zenith flight orientations to determine the effect of varying solar to AO ratios on Ey. Common spacecraft materials including Teflon FEP, white Tedlar and Upilex-S were included on multiple MISSE missions so erosion dependence on environment exposure can be determined. The PCE-1 includes epoxy composite samples with varying ZnO levels to determine the effect of inorganic filler level on AO durability. And, a variety of samples were flown to characterize AO scattering and AO undercutting processes. All four PCE experiments include samples to provide better insight into radiation durability of polymers and composites. The MISSE-9 PCE-1 includes Teflon FEP tensile samples flown in the wake and zenith direction so variations in radiation exposure from the different flight directions can provide insight into radiation induced embrittlement of Teflon FEP. Teflon FEP tensile samples were also flown in the wake direction as part of the MISSE-13 PCE-4. In addition, shape memory alloys, shape memory composites, melanin based composites, stressed and unstressed gossamer sun shield materials, coated and uncoated docking seal samples, and new solar cell cover slides were flown for space radiation durability and/or shielding assessment. This paper provides an overview of Glenn’s PCE 1-4 MISSE-FF experiments and provides initial post-flight observations and results.

atomic oxygen

Materials International Space Station Experiment-9 (MISSE-9) Polymers and Composites Experiment

Spacecraft in low Earth orbit (LEO) are subjected to harsh environmental conditions, including radiation (cosmic rays, ultraviolet, x-ray, and charged particle radiation), micrometeoroids and orbital debris, temperature extremes, thermal cycling, and atomic oxygen (AO). These environmental exposures can result in erosion, embrittlement and optical property degradation, threatening spacecraft performance and durability. To increase our understanding of effects such as AO erosion and radiation induced embrittlement of spacecraft materials, NASA Glenn has developed a series of experiments flown as part of the Materials International Space Station Experiment (MISSE) missions on the exterior of the International Space Station (ISS). These experiments have provided critical LEO space environment durability data such as AO erosion data for many materials and mechanical properties changes after long term space exposure. In continuing these studies, a new experiment called the Polymers and Composites Experiment has been selected for flight on the MISSE-Flight Facility (MISSE-FF). The Polymers and Composites Experiment will be flown as part of the MISSE-9 mission, the inaugural mission of MISSE-FF manifested on SpaceX-14. This experiment includes 138 samples being flown in ram, wake or zenith orientations for space environmental durability assessment. The primary objective is to determine the LEO AO erosion yield, Ey (the volume loss per incident oxygen atom (cm3/atom)), of polymers, composites, and coated samples, as a function of solar irradiation and AO fluence. In addition, epoxy samples with varying levels of ZnO powder are included to study the effect of filler quantity on AO erosion. An AO Scattering Chamber is included to help improve the understanding of AO scattering mechanisms for improved AO undercutting modeling. Indium tin oxide (ITO) coated samples are included to validate the durability of ITO conductive coatings in LEO. Tensile samples of Teflon fluorinated ethylene propylene (FEP) of varying thicknesses and back-surface coatings will be flown in wake and zenith orientations to study radiation embrittlement versus thickness, and the effect of heating on FEP embrittlement. Finally, shape memory composite and cosmic ray shielding samples will be flown for LEO durability assessment. This paper presents an overview of the MISSE-9 Polymers and Composites Experiment.

Embrittlement

NASA Tech Briefs, August 2012

Topics covered include: Mars Science Laboratory Drill; Ultra-Compact Motor Controller; A Reversible Thermally Driven Pump for Use in a Sub-Kelvin Magnetic Refrigerator; Shape Memory Composite Hybrid Hinge; Binding Causes of Printed Wiring Assemblies with Card-Loks; Coring Sample Acquisition Tool; Joining and Assembly of Bulk Metallic Glass Composites Through Capacitive Discharge; 670-GHz Schottky Diode-Based Subharmonic Mixer with CPW Circuits and 70-GHz IF; Self-Nulling Lock-in Detection Electronics for Capacitance Probe Electrometer; Discontinuous Mode Power Supply; Optimal Dynamic Sub-Threshold Technique for Extreme Low Power Consumption for VLSI; Hardware for Accelerating N-Modular Redundant Systems for High-Reliability Computing; Blocking Filters with Enhanced Throughput for X-Ray Microcalorimetry; High-Thermal-Conductivity Fabrics; Imidazolium-Based Polymeric Materials as Alkaline Anion-Exchange Fuel Cell Membranes; Electrospun Nanofiber Coating of Fiber Materials: A Composite Toughening Approach; Experimental Modeling of Sterilization Effects for Atmospheric Entry Heating on Microorganisms; Saliva Preservative for Diagnostic Purposes; Hands-Free Transcranial Color Doppler Probe; Aerosol and Surface Parameter Retrievals for a Multi-Angle, Multiband Spectrometer LogScope; TraceContract; AIRS Maps from Space Processing Software; POSTMAN: Point of Sail Tacking for Maritime Autonomous Navigation; Space Operations Learning Center; OVERSMART Reporting Tool for Flow Computations Over Large Grid Systems; Large Eddy Simulation (LES) of Particle-Laden Temporal Mixing Layers; Projection of Stabilized Aerial Imagery Onto Digital Elevation Maps for Geo-Rectified and Jitter-Free Viewing; Iterative Transform Phase Diversity: An Image-Based Object and Wavefront Recovery; 3D Drop Size Distribution Extrapolation Algorithm Using a Single Disdrometer; Social Networking Adapted for Distributed Scientific Collaboration; General Methodology for Designing Spacecraft Trajectories; Hemispherical Field-of-View Above-Water Surface Imager for Submarines; and Quantum-Well Infrared Photodetector (QWIP) Focal Plane Assembly.

Source record

Aperture, A Large Telescope Using Magnetostriction For Post Deployment Corrections: Final Technical Report of NASA Innovative Advanced Concepts (NIAC) Phase I

In summary, astronomical as well as Earth observing applications of the future are counting on larger aperture telescopes than are currently available. Several groups have been working on the topic of enabling large (about 16-m diameter) UV-Vis telescopes for many years. The unique feature of our concept is that magnetic films are used rather than electrostatic films or piezo-electrostatic pads. Our magnetic film concept allows for contiguous correction along the surface, does not require a hard wire connection, and does not require continuous external application of the field. There are many unknowns related to the initial accuracy of the deployed figure prior to the magnetic write head corrections. The length scale over which the corrections need to be applied is also of concern. For, although approximately mm length scale corrections can be made with the MSM plus write head technology, the number of 1 mm² patches in a 16 m diameter mirror is too large to contemplate applying individual corrections to each individual patch. However, deployment strategies and the materials available continue to evolve, in particular shape memory composites (SMCs) [34] or alloys (SMAs) [41], such that at this time we see no show-stoppers for this concept. Furthermore, the ability to tune deformations down to much (factors of 10-100) smaller (m) scale opens the futuristic possibility of improving the figure well beyond Strehl values of 90%.

APERTURE

Self-Deploying Trusses Containing Shape-Memory Polymers

Composite truss structures are being developed that can be compacted for stowage and later deploy themselves to full size and shape. In the target applications, these smart structures will precisely self-deploy and support a large, lightweight space-based antenna. Self-deploying trusses offer a simple, light, and affordable alternative to articulated mechanisms or inflatable structures. The trusses may also be useful in such terrestrial applications as variable-geometry aircraft components or shelters that can be compacted, transported, and deployed quickly in hostile environments. The truss technology uses high-performance shape-memory-polymer (SMP) thermoset resin reinforced with fibers to form a helical composite structure. At normal operating temperatures, the truss material has the structural properties of a conventional composite. This enables truss designs with required torsion, bending, and compression stiffness. However, when heated to its designed glass transition temperature (Tg), the SMP matrix acquires the flexibility of an elastomer. In this state, the truss can be compressed telescopically to a configuration encompassing a fraction of its original volume. When cooled below Tg, the SMP reverts to a rigid state and holds the truss in the stowed configuration without external constraint. Heating the materials above Tg activates truss deployment as the composite material releases strain energy, driving the truss to its original memorized configuration without the need for further actuation. Laboratory prototype trusses have demonstrated repeatable self-deployment cycles following linear compaction exceeding an 11:1 ratio (see figure).

Schueler, Robert M.

Improved Damage Resistant Composite Materials Incorporating Shape Memory Alloys

Metallic shape memory alloys (SMA) such as nitinol have unique shape recovery behavior and mechanical properties associated with a material phase change that have been used in a variety of sensing and actuation applications. Recent studies have shown that integrating nitinol-SMA actuators into composite materials increases the composite material's functionality. Hybrid composites of conventional graphite/epoxy or glass/epoxy and nitinol-SMA elements can perform functions in applications where monolithic composites perform inadequately. One such application is the use of hybrid composites to function both in load bearing and armor capacities. While monolithic composites with high strength-to-weight ratios function efficiently as loadbearing structures, because of their brittle nature, impact loading can cause significant catastrophic damage. Initial composite failure modes such as delamination and matrix cracking dissipate some impact energy, but when stress exceeds the composite's ultimate strength, fiber fracture and material perforation become dominant. One of the few methods that has been developed to reduce material perforation is hybridizing polymer matrix composites with tough kevlar or high modulus polyethynylene plies. The tough fibers increase the impact resistance and the stiffer and stronger graphite fibers carry the majority of the load. Similarly, by adding nitinol-SMA elements that absorb impact energy through the stress-induced martensitic phase transformation, the composites' impact perforation resistance can be greatly enhanced. The results of drop-weight and high velocity gas-gun impact testing of various composite materials will be presented. The results demonstrate that hybridizing composites with nitinol-SMA elements significantly increases perforation resistance compared to other traditional toughening elements. Inspection of the composite specimens at various stages of perforation by optical microscope illustrates the mechanisms by which perforation is initiated. Results suggest that the out-of-plane transverse shear properties of the composite and nitinol elements have a significant effect on the perforation resistance. Applications that can utilize the hybrid composites effectively will also be presented with the experimental studies.

Paine, Jeffrey S. N.

Precipitation Hardenable High Temperature Shape Memory Alloy

A composition of the invention is a high temperature shape memory alloy having high work output, and is made from (Ni+Pt+Y),Ti(100-x) wherein x is present in a total amount of 49-55 atomic % Pt is present in a total amount of 10-30 atomic %, Y is one or more of Au, Pd. and Cu and is present in a total amount of 0 to 10 atomic %. The alloy has a matrix phase wherein the total concentration of Ni, Pt, and the one or more of Pd. Au, and Cu is greater than 50 atomic %.

Noebe, Ronald Dean

Challenges and Progress in the Development of High-Temperature Shape Memory Alloys Based on NiTiX Compositions for High-Force Actuator Applications

Interest in high-temperature shape memory alloys (HTSMA) has been growing in the aerospace, automotive, process control, and energy industries. However, actual materials development has seriously lagged component design, with current commercial NiTi alloys severely limited in their temperature capability. Additions of Pd, Pt, Au, Hf, and Zr at levels greater than 10 at.% have been shown to increase the transformation temperature of NiTi alloys, but with few exceptions, the shape memory behavior (strain recovery) of these NiTiX systems has been determined only under stress free conditions. Given the limited amount of basic mechanical test data and general lack of information regarding the work attributes of these materials, a program to investigate the mechanical behavior of potential HTSMAs, with transformation temperatures between 100 and 500 C, was initiated. This paper summarizes the results of studies, focusing on both the practical temperature limitations for ternary TiNiPd and TiNiPt systems based on the work output of these alloys and the ability of these alloys to undergo repeated thermal cycling under load without significant permanent deformation or "walking". These issues are ultimately controlled by the detwinning stress of the martensite and resistance to dislocation slip of the individual martensite and austenite phases. Finally, general rules that govern the development of useful, high work output, next-generation HTSMA materials, based on the lessons learned in this work, will be provided

Padula, Santo, II