DEVELOPMENT OF SHAPE MEMORY ALLOYS- CHALLENGES AND SOLUTIONS€¦ · DEVELOPMENT OF SHAPE MEMORY...

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DEVELOPMENT OF SHAPE MEMORY ALLOYS-

CHALLENGES AND SOLUTIONS

Othmane Benafan– NASA GlennHigh Temperature & Smart Alloys Branch

Materials and Structures Division

Presentation for: The Boeing Company, Berkeley, MOSept. 09, 2016

https://ntrs.nasa.gov/search.jsp?R=20170003885 2020-05-02T11:02:05+00:00Z

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• Materials:

– Develop new shape memory alloys ranging from cryogenic to high temperature for use

in adaptive structures, and lightweight, solid-state actuation systems .

– Adjust material properties though alloying, processing, and thermo mechanical

understanding.

– Identify methods to establish good stability, durability, workability, and work output

amongst others

• Infrastructure:

– Develop laboratory testing capability and methods to evaluate and characterize SMA

properties/ performance.

– Generate material(s) data sheets and databases

– Determine test standards/methodologies

– Component or subcomponent testing/modeling

• Applications:

– Identify/build applications to benefit the aeronautics and space design challenges

– Design methodologies

– Commercialization

Our Goals – Materials, Infrastructure, Applications

2

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• Materials:

– Develop new shape memory alloys ranging from cryogenic to high temperature for use

in adaptive structures, and lightweight, solid-state actuation systems .

– Adjust material properties though alloying, processing, and thermo mechanical

understanding.

– Identify methods to establish good stability, durability, workability, and work output

amongst others

• Infrastructure:

– Develop laboratory testing capability and methods to evaluate and characterize SMA

properties/ performance.

– Generate material(s) data sheets and databases

– Determine test standards/methodologies

– Component or subcomponent testing/modeling

• Applications:

– Identify/build applications to benefit the aeronautics and space design challenges

– Design methodologies

– Commercialization

Our Goals – Materials, Infrastructure, Applications

3

Design “The” material

Design “WITH” material

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4

SMA Labs: Thermomechanical Testing

Cold Temperature Testing Multiaxial Testing

Durability Testing• Uniaxial loading (tensile loading)

• Torsion (torque tubes)

• Fast cycling times (5 minutes cycle)

Uniaxial High Temperature

Testing

Capabilities:

• 5-22 kip load capacity

• Temperature: -125 °C to 500 °C

• Servohydraulic & electromechanical

• Load, stoke, strain control

• Tension and compression

Capabilities:

• Axial-Torsion loading

• Optical strain measurement

• Temperature > 600 ° C

• Torque rating : 220 N-m

• Force rating: 22 kN

Capabilities:

• Laser strain

measurement

• High temperature

extensometers

• Tension/compression

• Force rating: 5-22kip

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Vacuum Induction

Melting

Vacuum Hot Press

Mechanical AlloyingWelding and Joining

Melting & Processing

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Hitachi S4700-FESEM

JEOL 8200 Electron ProbePhilips CM200 TEM

AURIGA™ Cross-

Beam Microscope

Analytical Sciences

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Development of Shape Memory Alloys:

Challenges and Lessons Learned

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Development of Shape Memory Alloys:

Challenges and Lessons Learned

Durability• Loading history

• Functional fatigue

• Structural fatigue

High transformation

temperatures• Above 100 °C

• Good work output

• Thermal stability

Dimensional stability • Cyclic stability

• Stress-strain relationship

Certification• Testing standards

• Material certification

• Database

Workability/Processing• Ductility

• Composition control

• Heat treatment

Modeling• Micromechanics

• Phenomenological

• Evolutions/transients

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Metals

NiTi, NiTiFe, NiTiNb, NiTiCu, NiTiPd,

NiFeGa, NiTiCo CuZn, CuZnAl, CuAlNi,

CuAlNiMn, CuSn FePt, FeMnSi, FeNiC

NiTiHf, NiTiZr, TiNiPd, TiNiPt,

ZrRh, ZrCu, ZrCu NiCo,

ZrCuNi CoTi, TiMo, TiNb,

TiTa, TiAu, UNb, TaRu, NbRu,

FeMnSi

AgCd

AuCd

CoNiAl

Magnetic/Ferromagnetic

NiMnGa, FePd, NiMnAl,

FePt, Dy, Tb, LaSrCuO,

ReCu, NiMnIn, CoNiGa

Polymers

Ceramics

PTFE, PU, Poly-caprolactone, EVA + nitrile

rubber, PE, Poly-cyclooctene, PCO– CPE blend

PCL–BA copolymer, Poly(ODVE)-co-BA,

EVA + CSM, PMMA,

Copolyesters, PET-PEG

ZrO2 (PSZ), MgO,

CeO2, PLZT, PNZST

Others

Thin films, hybrids…

55 Years after Nitinol Discovery

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Development of Shape Memory Alloys:

High Temperature Shape Memory Alloys (HTSMAs)

Ma et al. (2010)

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Development of Shape Memory Alloys:

NiTi –Based HTSMAs NiTiHf NiTiPd

temperature (°C)

stra

in (

%)

G. Bigelow

temperature (°C)

stra

in (

%)

NiTiPt

R. Noebe

NiTiAu

temperature (°C)

stra

in (

%)

G. Bigelow

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Development of Shape Memory Alloys:

HTSMAs Summary

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Development of Shape Memory Alloys:

Challenges and Lessons Learned

Durability• Loading history

• Functional fatigue

• Structural fatigue

High transformation

temperatures• Above 100 °C

• Good work output

• Thermal stability

Dimensional stability • Cyclic stability

• Stress-strain relationship

Certification• Testing standards

• Material certification

• Database

Workability/Processing• Ductility

• Composition control

• Heat treatment

Modeling• Micromechanics

• Phenomenological

• Evolutions/transients

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Development of Shape Memory Alloys:

How about Dimensional Stability?

How to make the material/actuator stable?

• Solution 1: Thermomechanical “training” (e.g., cycling, reverse

loading…)

• Solution 2: Alloying and microstructural control (e.g.,

precipitation hardening, Ni-content…)

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Microstructural Control towards Stability

(400)H

ZA:[110]B2||[010]H

(001)B2

200nm500nm

0

30

60

90

120

150

180

210

240

270

300

330

{110}A

latt

ice s

train

(%

)

0.5

0

-0.5

d-spacing (Å)1 1.5 2 2.5 3

0

1

0

1

inte

nsi

ty (

a.u

.)

(b)

(c)

tem

per

atu

re (

ºC)

30

hea

tin

gco

oli

ng

230

inte

nsi

ty (

a.u

.)

30

As

Af

Ms

Mf

(10

0) A

(110) A

(111

) A

(21

0) A

(221) A

(211

) A

(011

) M

(10

0) M

(110) M

(111

) M(1

10) M

(111

) M

(10

2) M

(03

0) M

(202) M

(32

0) A

reta

ined

B1

9'

Asneutron

55

NiT

iN

iTiP

dN

iTiH

f

OutcomeIn situ diffractionElectron diffraction

10 nm precipitates

20 nm precipitates

114M,T

110T002T

112T

110M

002M112M

15

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Development of Shape Memory Alloys:

Challenges and Lessons Learned

Durability• Loading history

• Functional fatigue

• Structural fatigue

High transformation

temperatures• Above 100 °C

• Good work output

• Thermal stability

Dimensional stability • Cyclic stability

• Stress-strain relationship

Certification• Testing standards

• Material certification

• Database

Workability/Processing• Ductility

• Composition control

• Heat treatment

Modeling• Micromechanics

• Phenomenological

• Evolutions/transients

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Lf

Li

17

Development of Shape Memory Alloys:

How about Durability/Fatigue?

• Loss of actuation strain

• Shifts in transformation characteristics (Hysteresis, temperatures…)

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Durability Assessment Underway…

Data exists up to 1000’s of

cycles, how about 1M cycles? Currently collecting durability

data on NiTiHf tubes

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Durability Assessment Underway…

Martensite Angle Actuation Angle- =Austenite Angle

Strain Actuation 1/∝ (Cycle Count × MPa per load)

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Development of Shape Memory Alloys:

Challenges and Lessons Learned

Durability• Loading history

• Functional fatigue

• Structural fatigue

High transformation

temperatures• Above 100 °C

• Good work output

• Thermal stability

Dimensional stability • Cyclic stability

• Stress-strain relationship

Certification• Testing standards

• Material certification

• Database

Workability/Processing• Ductility

• Composition control

• Heat treatment

Modeling• Micromechanics

• Phenomenological

• Evolutions/transients

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Processing and Workability of HTSMAs

NiTiPt

60 mil NiTi-20Pt rod

44 & 5 mil NiTiPt

5 mil NiTiPt wire

Induction Melt +

Homogenization

Extrusion

Wire Drawing

Wire Grinding

Multiple-Pass Extrusion

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Processing and Workability of HTSMAs

NiTiHf

High temperature extrusion proved to be

problematic (C. Wojcik 2008)

Successful hot rolled button (C. Wojcik

2008)

Successful hot extrusion (rods and tubes)

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Development of Shape Memory Alloys:

Challenges and Lessons Learned

Durability• Loading history

• Functional fatigue

• Structural fatigue

High transformation

temperatures• Above 100 °C

• Good work output

• Thermal stability

Dimensional stability • Cyclic stability

• Stress-strain relationship

Certification• Testing standards

• Material certification

• Database

Workability/Processing• Ductility

• Composition control

• Heat treatment

Modeling• Micromechanics

• Phenomenological

• Evolutions/transients

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ASTM Standards for biomedical and

or superelastic

• F2004-05

• F2005-05

• F2063-05

• F2082-06

• F2516-07

• F2633-07

Certification and Test Standards

ASTM Standards for SMA Actuation

• None

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ASTM Standards for biomedical and

or superelastic

• F2004-05

• F2005-05

• F2063-05

• F2082-06

• F2516-07

• F2633-07

Certification and Test Standards

ASTM Standards for SMA Actuation

• None

Deliver the first ever regulatory agency-accepted material specification and test standards

for shape memory alloys as employed as actuators for commercial and military aviation

applications

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Promoting Growth of SMA Technologies….

26

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Development of Shape Memory Alloys:

Challenges and Lessons Learned

Durability• Loading history

• Functional fatigue

• Structural fatigue

High transformation

temperatures• Above 100 °C

• Good work output

• Thermal stability

Dimensional stability • Cyclic stability

• Stress-strain relationship

Certification• Testing standards

• Material certification

• Database

Workability/Processing• Ductility

• Composition control

• Heat treatment

Modeling• Micromechanics

• Phenomenological

• Evolutions/transients

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Research and Understanding of Shape Memory Alloys

10-10 10-9 10-8 10-7 10-6 10-5 10-4 10-3 10-2

nm mm mmÅ m

10-1 100

STRUCTURAL SCALE

(COMPONENTS)

MICRO-SCALE

(MICROSTRUCTURES)

ATOMIC SCALE

(NANOMATERIALS)

0

200

400

600

800

0 5 10 15 20

stre

ss (

MP

a)

strain (%)

15%

10%

5%

8%

13%

18%

(b)

0%

0.0

0

8.0

0

1.0

0

2.0

0

3.0

0

4.0

0

5.0

0

6.0

0

7.0

0

1. Applied Research

2. Alloy Processing & Development

3. Testing and Modeling

4. Applications

28

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Complex Responses, Many Responses Uniaxial (tension/compression)

Torsion

Multiaxial

Durability

0

5

10

15

20

25

0 50 100 150 200 250

coolingheating

strain

(%

)

temperature (ºC)

-800

-600

-400

-200

0

200

400

600

-2 -1 0 1 2

stres

s (M

Pa

)

strain (%)

Isothermal monotonic

Isobaric cyclic

Isothermal cyclic

0

10

20

30

40

50

40 80 120 160 200

heatingcooling

an

gle

of

twis

t (º

)

temperature (ºC)

T = 3.4 N.m

(b)

0

2

4

0

100

200

0 1000 2000 3000 4000 5000to

rq

ue (

N.m

)

tem

peratu

re (

ºC)

time (s)

Control mode: torque/load

(a)

• Proportional/non-proportional

loading

• 3D strain measurement

• Torque/force/twist/displacement

control capability

-400

-200

0

200

400

-400 -200 0 200 400

shea

r s

tres

s (M

Pa

)

axial stress (MPa)

0

200

400

600

800

0 5 10 15 20

stre

ss (

MP

a)

strain (%)

15%

10%

5%

8%

13%

18%

(b)

0% strain control

-100

0

100

200

300

400

500

0 40 80 120 160

stre

ss (

MP

a)

temperature (ºC)

Isostrain cyclic

• New frames for durability testing are underway

• Durability analysis of sample and components

• Generate data for existing materials

Geometries

Hot grip testing

29

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Materials – High and Low Temperature SMA

0 °C

Low Temperature SMAs

NiTi

NiTiFe

NiTiCo/Cr

NiTiCu

NiTiHf/Zr

High Temperature SMAs

NiTiHf

NiTiZr

NiTiPd

NiTiPt

NiTiAu

Cold Hot

30

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Design of Actuators- Torque tubes example

.5” Ø

.375” Ø

.2” Ø

= τ

Material and

geometry effects

Possible Stress Gradients

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Some SMA Components

32

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Shape Memory Alloy Applications

Space

SMA Bellowso Dynamic sealing

o Fluid handling

o Flexibility (structure alignment)

SMA Spring Tireo Superelastic technology

o Lunar rovers

o Terrestrial tires

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SMA Thermal Switcho Thermal management

o Clean & spark-free operation

o Passive or active control

SMA Bearingso Corrosion resistant

o Non-galling properties

o High yield

SMA Docking Coupling o Cryogenic transfer coupling

o Orbital propellant depots

o Propellant handling/protection

RXN

SMA rock splitters

33

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Shape Memory Alloy Applications

Aeronautics

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Adaptive Fan Blade o Embedded SMA actuators

o Aerodynamic efficiency

o Specific fuel consumption reduction

SMA Cellular Structures o Airframe and engine

components

o Morphing airfoils

o Light weight trusses

+

A

Variable Area Nozzle o High bypass turbofan

o SMA torque tubes provide flap rotation

o Engine noise reduction

CDI

The Mars Atmosphere and Volatile

EvolutioN (MAVEN) mission.o SMA Pinpullers (From TiNi Aerospace) were used to secure

and release deployables

34

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Shape Memory Alloy Applications

Non-Aerospace Potential

Oil and Gas Industryo SmartRAMTM actuators (LMP)

o SMA couplings (Aerofit Inc)

o Deep-water valves/shut off valves

o Self-torquing fasteners

Medical Industry o Surgical tools

o Stents and implants

o Glasses frames Automotive Industry o Louvers

o Quiet actuators

o Door handle

GM

Other Applications o Home appliances

o Electronics

o Transportation

o Air conditioners

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NASA SMA Team and Collaborators

SMA Team at NASA GRC

• Othmane Benafan

• Santo Padula II

• Glen Bigelow

• Anita Garg

• Darrell Gaydosh

• Timothy Halsmer

• Ron Noebe

• (Branch Chief: Joyce Dever)

Collaborators

36

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Thank You