Cornerstone Research Group Inc. (CRG) has developed environmental exposure tracking (EET) sensors using shape
memory polymers (SMP) to monitor the degradation of perishable items, such as munitions, foods and beverages, or
medicines, by measuring the cumulative exposure to temperature and moisture. SMPs are polymers whose qualities have
been altered to give them dynamic shape "memory" properties. Under thermal or moisture stimuli, the SMP exhibits a
radical change from a rigid thermoset to a highly flexible, elastomeric state. The dynamic response of the SMP can be
tailored to match the degradation profile of the perishable item. SMP-based EET sensors require no digital memory or
internal power supply and provide the capability of inexpensive, long-term life cycle monitoring of thermal and moisture
exposure over time.
This technology was developed through Phase I and Phase II SBIR efforts with the Navy. The emphasis of current
research centers on transitioning SMP materials from the lab bench to a production environment. Here, CRG presents the
commercialization progress of thermally-activated EET sensors, focusing on fabrication scale-up, process refinements,
and quality control. In addition, progress on the development of vapor pressure-responsive SMP (VPR-SMP) will be
discussed.
KEYWORDS: Composites, Structural health monitoring, Control systems, Nondestructive evaluation, Sensors, Inspection, Software development, Intelligence systems, Data modeling, Systems modeling
Cornerstone Research Group Inc. (CRG) has developed and demonstrated a composite structural solution called
reflexive composites for aerospace applications featuring CRG's healable shape memory polymer (SMP) matrix. In
reflexive composites, an integrated structural health monitoring (SHM) system autonomously monitors the structural
health of composite aerospace structures, while integrated intelligent controls monitor data from the SHM system to
characterize damage and initiate healing when damage is detected. Development of next generation intelligent
controls for reflexive composites were initiated for the purpose of integrating prognostic health monitoring
capabilities into the reflexive composite structural solution.
Initial efforts involved data generation through physical inspections and mechanical testing. Compression after
impact (CAI) testing was conducted on composite-reinforced shape memory polymer samples to induce damage and
investigate the effectiveness of matrix healing on mechanical performance. Non-destructive evaluation (NDE)
techniques were employed to observe and characterize material damage. Restoration of mechanical performance
was demonstrated through healing, while NDE data showed location and size of damage and verified mitigation of
damage post-healing. Data generated was used in the development of next generation reflexive controls software.
Data output from the intelligent controls could serve as input to Integrated Vehicle Health Management (IVHM)
systems and Integrated Resilient Aircraft Controls (IRAC). Reflexive composite technology has the ability to
reduce maintenance required on composite structures through healing, offering potential to significantly extend
service life of aerospace vehicles and reduce operating and lifecycle costs.
Shape memory polymers (SMPs) are polymers that can recover a large pre-deformed shape in response to environmental
stimuli, such as temperatures, light, etc. For a thermally induced amorphous shape memory polymer, the pre-deformation
and recovery of the shape require the material to traverse the glassy transition temperature Tg under constrained or free
conditions. In this paper, effects of thermal rates to mechanical behaviors of SMP under constrained condition were
investigated. The stress-temperature behavior demonstrates a faster stress decrease than thermal contraction during
cooling and a characteristic stress overshoot during constrained reheating. These observations were explained by a one
dimensional (1D) model that considers the non-equilibrium structure relaxation and viscoelastic behavior of the material.
Cornerstone Research Group Inc. has developed reflexive composites achieving increased vehicle
survivability through integrated structural awareness and responsiveness to damage. Reflexive
composites can sense damage through integrated piezoelectric sensing networks and respond to damage
by heating discrete locations to activate the healable polymer matrix in areas of damage. The polymer
matrix is a modified thermoset shape memory polymer that heals based on phenomena known as
reptation.
In theory, the reptation healing phenomena should occur in microseconds; however, during
experimentation, it has been observed that to maximize healing and restore up to 85 % of mechanical
properties a healing cycle of at least three minutes is required. This paper will focus on work conducted
to determine the healing mechanisms at work in CRG's reflexive composites, the optimal healing cycles,
and an explanation of the difference between the reptation model and actual healing times.
Cornerstone Research Group, Inc. (CRG) is developing a unique adaptive wing structure intended to enhance the capability of loitering Unmanned Air Vehicles (UAVs). In order to tailor the wing design to a specific application, CRG has developed a wing structure capable of morphing in chord and increasing planform area by 80 percent. With these features, aircraft will be capable of optimizing their flight efficiency throughout the entire mission profile. The key benefit from this morphing design is increased maneuverability, resulting in improved effectiveness over the current design. During the development process CRG has overcome several challenges in the design of such a structure while incorporating advanced materials capable of maintaining aerodynamic shape and transferring aerodynamic loads while enabling crucial changes in planform shape. To overcome some of these challenges, CRG is working on integration of their shape memory polymer materials into the wing skin to enable seamless morphing. This paper will address the challenges associated with the development of a morphing aerospace structure capable of such large shape change, the materials necessary for enabling morphing capabilities, and the current status of the morphing program within CRG.
Continuous product development and technology integration efforts using shape memory polymers (SMPs) have uncovered a need for faster response times. As with most smart materials, SMP responds to a specific stimulus. Traditionally SMP is triggered by thermal stimulus; increasing the temperature of the SMP above a Tg will transition the polymer from a glassy state to a rubbery state. The transition is reversible upon cooling below the Tg. It has been determined that many SMP applications can be significantly enhanced with non-thermal triggering. Non-thermal triggering eliminates the need for heating mechanisms and reduces cycle time. Furthermore, it has been found that with a faster response time many new applications become viable. Previous successful attempts have been made to improve response time of SMP by increasing its thermal conductivity with various thermally conductive additives1. However, thermal heating and cooling of polymers and composites of substantial thickness, thermally conductive or not, takes time.
In an effort to facilitate system integration and increase the response time of SMP, researchers at Cornerstone Research Group, Inc. (CRG) have sought to eliminate the thermal dependency of SMP by developing light-activated shape memory polymer (LASMP). In this work, monomers which contain photo-crosslinkable groups in addition to the primary polymerizable groups were developed. These monomers were formulated and cured with other monomers to form LASMP. The mechanical properties of these materials, the kinetics, and the reversibility of the light-activated shape memory effect were studied. The near-, mid-, and far-term potential of this new material technology for system level applications is discussed.
Cornerstone Research Group, Inc. (CRG) has developed processes to make molds for casting and mandrels for filament winding composite parts from novel shape memory polymers (SMPs). For external molding, the SMP tooling system is capable of being thermally formed into a precise negative image of a master part, cooled, and made to retain the new shape. For filament winding mandrels, internal SMP mandrels can be used and easily extracted after curing. CRG has developed the ability to fabricate SMP materials from a wide range of polymer systems. Veriflex, the trademark name for CRG's shape memory polymer resin systems, functions on thermal activation customizable from -20°F to 520°F. These materials can withstand the elevated temperatures that are needed to cure composite parts without deformation and offer a gentle, simple demolding process. After the composite part has cured, the mold is raised above the Tg, which allows it to retract to its memory shape. SMP tooling processes provide the opportunity to mitigate the drawbacks of traditional fabrication techniques for advanced composite parts. This tooling system also possesses versatility in size variations, including being capable of micro (nanometers) to macro (meters) replication.
Cornerstone Research Group, Inc. (CRG), with specific no-cost guidance and support from Lockheed Martin, proposed to significantly increase the capability of loitering Unmanned Air Vehicles (UAVs) by developing a unique adaptive wing structure. This technology will offer significant operational benefit to air vehicles of this type currently under development. The development of this adaptive wing structure will enable such aircraft to adapt their wing configuration to maximize efficiency in each flight regime experienced during their mission. Additionally, the benefits of this development program will enhance the agility and maneuverability of the vehicle; therefore increasing its mission capability. The specific morphing ability CRG proposed to develop was a controlled expansion and contraction of the wing chord, which increases the wing planform area and therefore the lift produced. CRG proved feasibility of this concept and developed a sub-scale prototype integrating smart materials developed at CRG.
This paper presents the current status of alignment techniques for a new class of liquid crystalline material being developed for both passive optical filtering/polarizing and latching electro-optic applications. This new glassy liquid crystal (GLC) material has the unique property of being electro-optic and fully latching. That is, in one state, the material has the properties of a conventional nematic liquid crystal, capable of being aligned with either an electric or magnetic field; while in its other state, it is an optical quality solid that maintains the molecular alignment set while in the fluid state. Molecular alignment of nematic GLC films is a critical technology necessary to develop high-performance, novel latching devices. The alignment of the nematic pendant component of GLCs directly correlates to the optical contrast, switching speed (turn-on time), and decay speed (turn-off time) of an active latching device. There has been little prior research conducted to assess conventional LC alignment techniques for use with GLCs. The processing and effectiveness of multiple alignment techniques will be discussed.
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