The development of efficient and accurate analysis techniques for morphing aerostructures incorporating shape
memory alloys (SMAs) continues to garner attention. These active materials have a high actuation energy density,
making them an ideal replacement for conventional actuation mechanisms in morphing structures. However,
SMA components are often exposed to the same highly variable environments experienced by the aeroelastic
assemblies into which they are incorporated. This is motivating design engineers to consider modeling fluidstructure
interaction for prescribing dynamic, solution-dependent boundary conditions. This work presents a
computational study of a particular morphing aerostructure with embedded, thermally actuating SMA ribbons
and demonstrates the effective use of fluid-structure interaction modeling. A cosimulation analysis is utilized to
determine the surface deflections and stress distributions of an example aerostructure with embedded SMA ribbons
using the Abaqus Finite Element Analysis (FEA) software suite, combined with an Abaqus Computational
Fluid Dynamics (CFD) processor. The global FEA solver utilizes a robust user-defined material subroutine which
contains an accurate three-dimensional SMA constitutive model. Variations in the ambient fluid environment are
computed using the CFD solver, and fluid pressure is mapped into surface distributed loads. Results from the
analysis are qualitatively validated with independently obtained data from representative flow tests previously
conducted on a physical prototype of the same aerostructure.
Control of jet noise continues to be an important research topic. Exhaust-nozzle chevrons have been shown to reduce jet
noise, but parametric effects are not well understood. Additionally, thrust loss due to chevrons at cruise suggests
significant benefit from active chevrons. The focus of this study is development of an active chevron concept for the
primary purpose of parametric studies for jet noise reduction in the laboratory and secondarily for technology
development to leverage for full scale systems. The active chevron concept employed in this work consists of a
laminated composite structure with embedded shape memory alloy (SMA) actuators, termed a SMA hybrid composite
(SMAHC). SMA actuators are embedded on one side of the neutral axis of the structure such that thermal excitation, via
joule heating, generates a moment and deflects the structure. The performance of two active chevron concepts is
demonstrated in the presence of representative flow conditions. One of the concepts is shown to possess significant
advantages for the proposed application and is selected for further development. Fabrication and design changes are
described and shown to produce a chevron prototype that meets the performance objectives.
Control of jet noise continues to be an important research topic. Exhaust-nozzle chevrons have been shown to reduce jet
noise, but parametric effects are not well understood. Additionally, thrust loss due to chevrons at cruise suggests
significant benefit from active chevrons. The focus of this study is development of an active chevron concept for the
primary purpose of parametric studies for jet noise reduction in the laboratory and technology development to leverage
for full scale systems. The active chevron concept employed in this work consists of a laminated composite structure
with embedded shape memory alloy (SMA) actuators, termed a SMA hybrid composite (SMAHC). SMA actuators are
embedded on one side of the bending axis of the structure such that thermal excitation generates a moment and deflects
the structure. Two active chevron concepts are demonstrated; one that is powered to immerse and one that is powered to
retract. A brief description of the chevron designs is followed by details of the fabrication approach. Results from
bench-top tests are presented and correlated with predictions from a numerical model. Very repeatable performance is
achieved with excellent agreement between predicted and measured results. Although the deflection requirement is not
achieved in the presented results, the approach to meeting the performance requirement is evident.
KEYWORDS: Actuators, Shape memory alloys, Composites, Temperature metrology, Infrared cameras, Control systems, Electronic test equipment, Cameras, Data acquisition, Lead
Control of jet noise continues to be an important research topic. Exhaust nozzle chevrons have been shown to reduce jet noise, but parametric effects are not well understood. Additionally, thrust loss due to chevrons at cruise suggests significant benefit from deployable chevrons. The focus of this study is development of an active chevron concept for the primary purpose of parametric studies for jet noise reduction in the laboratory and technology development to leverage for full scale systems. The active chevron concept employed in this work consists of a laminated composite structure with embedded shape memory alloy (SMA) actuators, termed a SMA hybrid composite (SMAHC). The actuators are embedded on one side of the middle surface such that thermal excitation generates a moment and deflects the structure. A brief description of the chevron design is given followed by details of the fabrication approach. Results from bench top tests are presented and correlated with numerical predictions from a model for such structures that was recently implemented in MSC.Nastran and ABAQUS. Excellent performance and agreement with predictions is demonstrated. Results from tests in a representative flow environment are also presented. Excellent performance is again achieved for both open- and closed-loop tests, the latter demonstrating control to a specified immersion into the flow. The actuation authority and immersion performance is shown to be relatively insensitive to nozzle pressure ratio (NPR). Very repeatable immersion control with modest power requirements is demonstrated.
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.
The usage of shape memory materials has extended rapidly to many fields, including medical devices, actuators, composites, structures and MEMS devices. For these various applications, shape memory alloys (SMAs) are available in various forms: bulk, wire, ribbon, thin film, and porous. In this work, the focus is on SMA hybrid composites with adaptive-stiffening or morphing functions. These composites are created by using SMA ribbons or wires embedded in a polymeric based composite panel/beam. Adaptive stiffening or morphing is activated via selective resistance heating or uniform thermal loads. To simulate the thermomechanical behavior of these composites, a SMA model was implemented using ABAQUS' user element interface and finite element simulations of the systems were studied. Several examples are presented which show that the implemented model can be a very useful design and simulation tool for SMA hybrid composites.
This study presents the status and results from an effort to design, fabricate, and test an adaptive jet engine chevron concept based upon embedding shape memory alloy (SMA) actuators in a composite laminate, termed a SMA hybrid composite (SMAHC). The approach for fabricating the adaptive SMAHC chevrons involves embedding prestrained Nitinol actuators on one side of the mid-plane of the composite laminate such that thermal excitation generates a thermal moment and deflects the structure. A glass-epoxy pre-preg/Nitinol ribbon material system and a vacuum hot press consolidation approach are employed. A versatile test system for control and measurement of the chevron deflection performance is described. Projection moire interferometry (PMI) is used for global deformation measurement and infrared (IR) thermography is used for 2-D temperature measurement and feedback control. A recently commercialized constitutive model for SMA and SMAHC materials is used in the finite element code ABAQUS to perform nonlinear static analysis of the chevron prototypes. Excellent agreement is achieved between the predicted and measured chevron deflection performance, thereby validating the design tool. Although the performance results presented in this paper fall short of the requirement, the concept is proven and an approach for achieving the performance objectives is evident.
A thermomechanical model for shape memory alloy (SMA) actuators and SMA hybrid composite (SMAHC) structures has been recently implemented in the commercial finite element codes MSC.Nastran and ABAQUS. The model may be easily implemented in any code that has the capability for analysis of laminated composite structures with temperature dependent material properties. The model is also relatively easy to use and requires input of only fundamental engineering properties. A brief description of the model is presented, followed by discussion of implementation and usage in the commercial codes. Results are presented from static and dynamic analysis of SMAHC beams of two types; a beam clamped at each end and a cantilevered beam. Nonlinear static (post-buckling) and random response analyses are demonstrated for the first specimen. Static deflection (shape) control is demonstrated for the cantilevered beam. Approaches for modeling SMAHC material systems with embedded SMA in ribbon and small round wire product forms are demonstrated and compared. The results from the commercial codes are compared to those from a research code as validation of the commercial implementations; excellent correlation is achieved in all cases.
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.
Shape memory alloys (SMAs) have enormous potential for a wide variety of applications. A large body of work exists on the characterization of the microstructure and stress-strain behavior of these alloys, Nitinol (NiTi) in particular. However, many attributes of these materials are yet to be fully understood. Previous work at NASA Langley Research Center (LaRC) has included fabrication of hybrid composite specimens with embedded Nitinol actuators and modeling of their thermomechanical behavior. An intensive characterization effort has been undertaken to facilitate fundamental understanding of the stress-strain behavior of this alloy in relation to its microstructure and to promote implementation of Nitinol in aerospace applications. Previous work revealed attributes of the Nitinol ribbon that were not easily rationalized with existing data in the literature. In particular, tensile behavior at ambient temperature showed significant dependence on the thermomechanical history prior to testing. The present work is focused on characterizing differences in the microstructure of Nitinol ribbons exposed to four different thermomechanical histories and correlation of the microstructure with tensile properties. Differential scanning calorimetry (DSC) and x-ray diffraction (XRD) analysis were employed to rationalize the microstructures present after exposure to various thermomechanical histories. Three of the Nitinol ribbon conditions were reversible upon heating (in the DSC) through the reverse transformation temperature (Af) to transform the microstructure to austenite. However, the prior thermomechanical conditioning for the Nitinol ribbon that reflected the entire fabrication procedure was found to have an irreversible effect on the microstructure, as it remained unchanged after repeated complete thermal cycles. Tensile tests were conducted to determine the effect of prior thermomechancial conditioning on both the tensile behavior of the Nitinol ribbons and the stress state of the microstructure. The stress-strain behavior of the Nitinol actuators appears to be governed by the interplay between two major variables: namely, microstructural constituents such as the R-phase and the martensite; and the stress state of these constituents (whether twinned with low residual stresses, or detwinned with high residual stresses). The most significant difference in the stress-strain behavior of the four conditions, the critical stress required to achieve an initial stress plateau, was found to depend on both the amount and stress state of R-phase present in the initial microstructure. Thus, the effect of prior thermomechanical processing is critical to the resulting tensile behavior of the Nitinol actuator. For numerical modeling inputs one must take into account the entire fabrication process on the Nitinol actuator.
This study presents results from experimental validation of a recently developed model for predicting the thermomechanical behavior of shape memory alloy hybrid composite (SMAHC) structures, composite structures with an embedded SMA constituent. The model captures the material nonlinearity of the material system with temperature and is capable of modeling constrained, restrained, or free recovery behavior from experimental measurement of fundamental engineering properties. A brief description of the model and analysis procedures is given, followed by an overview of a parallel effort to fabricate and characterize the material system of SMAHC specimens. Static and dynamic experimental configurations for the SMAHC specimens are described and experimental results for thermal post-buckling and random response are presented. Excellent agreement is achieved between the measured and predicted results, fully validating the theoretical model for constrained recovery behavior of SMAHC structures.
Results from an effort to fabrication shape memory alloy hybrid composite (SMAHC) test specimens and characterize the material system are presented in this study. The SMAHC specimens are conventional composite structures with an embedded SMA constituent. The fabrication and characterization work was undertaken to better understand the mechanics of the material system, address fabrication issues cited in the literature, and provide specimens for experimental validation of a recently developed thermomechanical model for SMAHC structures. Processes and hardware developed for fabrication of the SMAHC specimens are described. Fabrication of a SMAHC laminate with quasi-isotropic lamination and ribbon-type Nitinol actuators embedded in the 0°layers is presented. Beam specimens are machined from the laminate and are the focus of recent work, but the processes and hardware are readily extensible to more practical structures. Results of thermomechanical property testing on the composite matrix and Nitinol ribbon are presented. Test results from the Nitinol include stress-strain behavior, modulus versus temperature, and constrained recovery stress versus temperature and thermal cycle. Complex thermomechanical behaviors of the Nitinol and composite matrix are demonstrated, which have significant implications for modeling of SMAHC structures.
The thermomechanical performance of a shape memory alloy hybrid composite beam specimen is demonstrated and used in a preliminary validation study of a recently developed constitutive model and finite element formulation for analysis of such structures. A brief description of the thermoelastic formulation is given. A material system consisting of a glass/epoxy matrix with embedded Nitinol actuators was chosen for this study. Results from Nitinol material characterization testing, beam specimen fabrication processes, and base acceleration testing for measuring the dynamic response performance in presented. Selected results from the dynamic test are shown, interpreted, and compared with predictions form the FE model. Elimination of a thermal post-buckling deflection by the activated SMA was observed. The fundamental natural frequency is shown to increase by a facto of 5.3 and the RMS displacement response is attenuated by a factor 6.4. Preliminary comparisons between predicted and measured performance is good. Discrepancies are attributable to insufficient knowledge of the matrix material properties at elevated temperature.
At last year's SPIE symposium, we reported results of an experiment on structural vibration damping of an F-15 underbelly panel using piezoelectric shunting with five bonded PZT transducers. The panel vibration was induced with an acoustic speaker at an overall sound pressure level (OASPL) of about 90 dB. Amplitude reductions of 13.45 and 10.72 dB were achieved for the first and second modes, respectively, using single- and multiple-mode shunting. It is the purpose of this investigation to extend the passive piezoelectric shunt- damping technique to control structural vibration induced at higher acoustic excitation levels, and to examine the controllability and survivability of the bonded PZT transducers at these high levels. The shunting experiments was performed with the Thermal Acoustic Fatigue Apparatus (TAFA) at the NASA Langley Research Center using the same F-15 underbelly panel. The TAFA is a progressive wave tube facility. The panel was mounted in one wall of the TAFA test section using a specially designed mounting fixture such that the panel was subjected to grazing-incidence acoustic excitation. Five PZT transducers were used with two shunt circuits designed to control the first and second modes of the structure between 200 and 400 Hz. We first determined the values of the shunt inductance and resistance at an OASPL of 130 dB. These values were maintained while we gradually increased the OASPL from 130 to 154 dB in 6-dB steps. During each increment, the frequency response function between accelerometers on the panel and the acoustic excitation measured by microphones, before and after shunting, were recorded. Good response reduction was observed up to the 148dB level. The experiment was stopped at 154 dB due to wire breakage from vibration at a transducer wire joint. The PZT transducers, however, were still bonded well on the panel and survived at this high dB level. We also observed shifting of the frequency peaks toward lower frequency when the OASPL was increased. Detailed experimental results will be presented.
KEYWORDS: Shape memory alloys, Composites, Matrices, Acoustics, Temperature metrology, Aerodynamics, Nickel, Finite element methods, Skin, Chemical elements
A finite element method for the analysis of thermal deflection and random response is presented for shape memory alloy (SMA) fiber reinforced composite plates subjected to thermal and acoustic loads. The formulation considers the temperature dependent nonlinear material properties of SMAs, the initial deflection and initial stresses, and the geometrical nonlinearity of large thermal deflections. A two-step solution procedure for the combined thermal and acoustic loading is employed consisting of an incremental method for the material nonlinearities and a Newton-Raphson iteration method for prediction of panel responses. Examples are given to show that it is feasible to eliminate the large thermal deflection completely and to reduce the dynamic random response within a given operating temperature range with the proper percentages of SMA volume fraction, prestrain and alloy composition.
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