600 MAGNETOSTRICTIVE MATERIALS

materials by using finite element analysis. It was foundtbat wall roughness on contact with the fluid is importantfor yield strengths, especially in low magnetic fields (9,10).Size and size distribution of the suspended particles alsoaffect the change in properties of the MR fluid when placedin a magnetic field (11,12). The combined effect of magneticand electric fields on magnetoelectrorheological materialshas also been explored (13). Tang and Conrad conducteda series of systematic experiments to characterize therheology of MR fluids from technological and scientificviewpoints (14).

APPLICATIONS

Because the state of MR materials can be controlled by tbestrength of an applied magnetic field, it is useful in applica-tions where variable performance is desired. Many smartsystems and structures would benefit from the changein viscosity or other material properties of MR materi-als. Beginning with the commercialization of MR fluidrotary brakes for use in aerobic exercise equipment in1995, application of magnetorheological material technol-ogy in real-world systems has grown steadily. The pastfew years have witnessed a blossoming commercializa-tion of MR fluid technology. MR fluid technoiogy has beenembraced by a number of manufacturers for inclusion ina diverse spectrum of products that are now commerciallyavailable (15):

• hnear MR dampers for real-time active vibrationalcontrol systems in heavy duty trucks

• linear and rotary brakes for low-cost, accurate, po-sitional and velocity control of pneumatic actuatorsystems

• rotary brakes to provide tactile force-feedback insteer-by-wire systems

• linear dampers for real-time gait control in advancedprosthetic devices

• adjustable sbock absorbers for NASCAR oval and dirttrack racing

Other applications that are near commerciahzationinclude

• low-cost MR sponge dampers for washing machines(16,17)

• very large MR fluid dampers for seismic damage miti-gation in civil engineering structures (17)

• large MR fluid dampers to control wind-induced vi-brations in cable-stayed bridges (18)

• real-time controlled sbock absorbers and struts for do-mestic automobiles

MR materials are also being considered for use in com-pliant mechanism design to change the compliance of flexi-ble members. This behavior can be modified as a functionof time resulting in a variably compliant mechanism (19).More applications are being considered and it is likely tbat.

as MR materials continue to improve, many more applica-tions will be fortbcoming.

BIBLIOGRAPHY

1. J. Rabinow, A/££ Trans. 67: 1308-1315 (1948).

2. Magnetic Fluid Torque and Force Transmitting Device. U.S.Pat. 2,575,360, 1951, J. Rabinow.

3. A. Duff, Phys. Rev. 4: 23 (1986).4. W.M. Winslow, J. Appl. Phys. 20: 1137-1140 (1949).5. http://www.mrfluid.com. 2001.6. D.J Klingenberg, Sci. Am. pp. 112-113 (Oct. 1993).7. J.M. Ginder and L.C. Davis, Appl. Pkys. Lett. 65: 3410-3412

(1994).

8. K.D. Weiss, T.G. Duclos, J.D. Carlson, M.J. Chrzan, and A.J.Margida, 1993 Int. Off-Highway & Powerplant Congr. Exposi-tion, SAE Technical Paper Series, #932451.

9. T. Miyamoto and M. Ota, Appt. Phys. Lett. 64: 1165-1167(1994).

10. E. Lemarie, and G. Bossis, J. Phys. D 24: 1473-1477 (1991).11. E. Lemaire, A. Mennier, G. Bossis, J. Liu, D. Felt, P.

Bashtovioi., and N. Matousseritch, J. Rheol. 39: 1011-1020(1995).

12. Method and Magnetorheological Fluid Formulations for In-creasing the Output of a Magnetorheological Fluid, US Pat.6,027,664, (2000), and US Pat. 5,900,184, (1999), K.D. Weiss,J.D. Carlson, and D.A. Nixon.

13. K. Koyama, Proc. 5th Int. Conf. Electro-Rheological, Magneto-Rheolagical Suspensions Associated Technol, Sheffield, U.K.,July 1995,

14. X. Tang and H. Conrad, J. Rheol.4(K6): 1167-1178 (1996).15. J.D. Carlson and J.L. Sproston, Proc. 7th Int. Conf. New Actu-

ators, Messe Bremen, Bremen, (2000), pp. 126-130.16. J.D. Carlson, Mach. Design, pp. 73-76, Feb. 22, (2001).17. J.D. Carlson, Motion Control, pp. 25-28, March 2001.18. B.F Spencer, Jr., G. Yang, J.D. Carlson, and M.K Sain, Proc.

2nd World Conf. Struct. Control, Kyoto, Japan, 1998.19. A.J.M. Henrie and L.L Howell, Proc. 43rd Int. SAMPE

Symp./Exhibition, Irvine, CA, 1998.

MAGNETOSTRICTIVE MATERIALS

MARCELO J . DAPINOOhio State UniversityColumbus, OH

INTRODUCTION

Magnetostrictive materials are a class of smart materi-als that can convert energy between the magnetic andelastic states. For this reason, magnetostrictive materialsand devices based on these materials are often referredto as transducers. Due to the bidirectional nature of tbisenergy exchange, magnetostrictive materials can be em-ployed for both actuation and sensing. Alloys based on thetransition metals iron, nickel, and cobalt in combinationwith certain rare-earth elements are currently employed inactuator and sensor systems in a broad range of industrial.

MAGNETOSTRICTIVE MATERIALS 601

biomedical, and defense applications. Because magne-tostriction is an inberent property of ferromagneticmaterials, it does not degrade over time as do some poledpiezoelectric substances. In addition, newer magnetostric-tive materials provide strains, forces, energy densities,and coupling coefficients tbat compete favorably with moreestablisbed technologies such as those based on piezo-electricity. As evidenced by the ever-increasing numberof patented magnetostrictive systems, transducer design-ers are finding new opportunities to employ magnetostric-tive materials in a wide variety of applications rangingfrom stand-alone transducers to complex smart structuresystems.

A number of design and modeling issues, bowever, com-plicate tbe implementation of magnetostrictive materi-als in certain applications in which other smart materialtechnologies are currently favored. For instance, due tothe required solenoid and related magnetic circuit compo-nents, magnetostrictive transducers are usually larger andbulkier than their piezoelectric or electrostrictive coun-terparts. Hence, they are employed primarily in appli-cations that require high strains and forces hut whereweight is not an issue. One additional consideration istbat the most technologically advanced magnetostrictivematerials are costly to manufacture. Advanced crystallinematerials are manufactured hy employing sophisticatedcrystal growth techniques that produce directional solid-ification along the drive axis of the transducer material.The manufacturing process also includes precision ma-chining of laminations, final diameters, and parallel endsof cut-to-length drivers, as well as thorough quality as-surance and performance evaluation throughout the pro-cess. These technological and cost-related problems bavebeen mitigated to some extent tbrough the advent of newmanufacturing techniques that have enabled more capablemagnetostrictive materials in various forms, includingamorphous or crystalline thin films, magnetostrictiveparticle-aligned polymer matrix composite structures, andsintered powder compacts suitable for mass production ofsmall irregular shapes. From the perspective of model-ing and control, magnetostrictive materials exhibit non-linear effects and bysteretic phenomena to a degree whichother smart materials, for instance electrostrictive com-pounds, do not. These effects are particularly exacerbatedat the moderate to high drive level regimes in which mag-netostrictive materials are most attractive. These issueshave been addressed tbrougb recent modeling tecbniques,and as new applications are developed, model accuracy andcompleteness will almost surely follow.

The term magnetostriction is a synonym for magneti-cally induced strain, and it refers to the change in physicaldimensions exhibited by most magnetic materials wbentbeir magnetization cbanges. Magnetization, defined asthe volume density of atomic magnetic moments, changesas a result of the reorientation of magnetic moments ina material. This reorientation can be brought ahout hyapplying either magnetic fields, heat or stresses. The lin-ear magnetostriction ^LjL that results from applying alongitudinal magnetic field on a sample of length L, illus-trated in Fig. 1, is the most commonly employed attributeof the magnetostrictive principle in actuator applications.

Though most ferromagnetic materials exhibit linear mag-netostriction, only a small number of compounds that con-tain rare-earth elements provide "giant" magnetostrictionsin excess of 1000 x 10"^. These large magnetostrictionsare a direct consequence of the strong magnetomechani-cal coupling that arises from the dependence of magneticmoment orientation on interatomic spacing. When a mag-netic field is applied to a magnetostrictive material, themagnetic moments rotate to the direction of the field andproduce deformations in the crystal lattice and strains inthe bulk material. Referring again to Fig. 1 wbicb per-tains to a material tbat bas positive magnetostriction, note

Figure 1. Joule magnetostriction produced by a magnetic field H.(a) H is approximately proportional to the current i that passesthrough the solenoid when a voltage is applied to it. (b) The ro-tation of magnetic dipoles changes the length of the sample, and(c) curve iiLjL vs, H obtained by varying the field sinusoidally.

602 MAGNETOSTRICTIVE MATERIALS

tbat the sample elongates irrespective of the direction ofrotation of the magnetic moments. A symmetrical magne-tostriction curve is ohtained when tbe field is cycled, as de-picted in Fig. lh,c. If stress is applied instead, the materialdeformations lead to magnetic moment reorientation and asubsequent change in the magnetization M. This magneti-zation change can he detected through the voltage inducedin a sensing solenoid wrapped around the sample, whichprovides a mechanism for sensing. In applications, eitherone sensing solenoid or a plurality of them arranged alongthe length of the driver can he placed inside of the drivingcoil. Alternatively, it is possible to employ only one solenoidto drive tbe magnetostrictive material and sense itsmagnetization changes. This configuration exhibits themajor disadvantage that additional signal processinghardware is required to extract the sensing voltage fromthe driving signal.

This article provides an overview of magnetostrictivematerials in tbe next section, followed by a description ofthe physical origin of magnetostriction and a discussionof material bebavior. The subsequent section is devoted tolinear magnetostriction, and other magnetostrictive effectsare discussed in the following section. Finally, a discussionof current transducer designs and modeling techniques ispresented.

MATERIALS OVERVIEW

The study of magnetostriction began in 1842 wben JamesP. Joule first observed tbat a sample of iron changes inlength when magnetized hy a magnetic field. Subsequentwork using otber materials sucb as nickel, cobalt, and theiralloys led to numerous applications, including telephonereceivers, hydrophones, scanning sonar, fog horns, oscil-lators, and torque sensors. During World War II, sonartransducer were driven primarily by nickel, which ex-hibits saturation magnetostrictions of ahout 50 x 10"^, Abreakthrough in magnetostrictive materials occurred in1963 when the largest-known magnetostrictions in therare-earth elements terbium and dysprosium were dis-covered. Tbe strains in tbese elements are of the orderof 10,000x10"^, or three orders of magnitude larger thanthose of nickel, but they are acbieved exclusively at cryo-genic temperatures. The temperature limitation and thefact that the field of piezoelectricity was gaining techni-cal maturity hindered the development of magnetostrictivematerials and led, in the early 1970s, to a search for a newclass of transducer materials capable of high room tem-perature strains. Highly magnetostrictive rare earths (R),principally samarium (Sm), terbium (Tb), and dysprosium(Dy), were combined witb tbe magnetic transition metalsnickel, cobalt, and iron by direct compound synthesis andby rapid sputtering into amorphous alloys. In contrast tothe normal Curie temperature behavior of the R-Ni andR-Co compounds, R-Fe compounds exhibit an increasein the Curie temperature as rare-earth concentrationincreases. Consequently, huge room temperature mag-netostrictions up to 3,000x10"^ were achieved, partic-ularly in the TbFe2 compound. However, because tbe

magnetostriction originates in tbe strain dependence ofmagnetic anisotropy, tbe large magnetostriction in thesecompounds is ohtained at tbe expense of large anisotropies.This poses a technological limitation since impracticallylarge fields of more than 2 MA/m are needed to hring thesecompounds to technical saturation.

Partial substitution of dysprosium for terbium in theTbFey system resulted in improved magnetostriction andanisotropy properties. The resulting pseudohinary com-pound TbosDyo7Fei9_i 95 has been available commerciallysince tbe 1980s under the name Terfenol-D (Ter = ter-bium, Fe = iron, N = Naval, O = Ordnance, L = Labo-ratory, D = dysprosium). The highest room temperaturemagnetostriction for Terfenol-D is l,600x 10"^ at a moder-ate saturation field of 0,16 MA/m, hut even larger mag-netostrictions up to 3,600x10"*^ are possible when thematerial is employed in transducers driven at resonance.Tbe utility of Terfenol-D as a rugged, high-power trans-ducer driver has been increasingly recognized in recentyears. At present, Terfenol-D is used in active noise andvibration control systems; low-frequency underwater com-munications (sonar); linear and rotational motors; ultra-sonic cleaning; machining and welding; micropositioning;and detecting motion, force, and magnetic fields. Terfenol-D is currently available in a variety of forms, includingmonolitbic rods (1,2), particle-aligned polymer matrix com-posites (3-5), and thin films (6,7), Because of the largemagnetostrictive anisotropy and strong magnetoelasticity,Terfenol-D and other pseudobinary rare-earth-iron com-pounds can be synthesized to exhibit a broad range of prop-erties (8).

A second new magnetostrictive material based on amor-phous metal was introduced in 1978, produced by rapidcooling of iron, nickel, and cobalt alloys together with oneor more of the elements silicon, boron, and phosphorus.These alloys are known commercially as Metglas (metallicglass) and are commonly produced in thin-ribbon geome-tries. Because of the extremely high coupling coefficientsik > 0,92), Metglas is a prime candidate for sensing appli-cations in which a mechanical motion is converted into anelectrical current or voltage (2).

The latest materials science research on magnetostric-tive materials includes the development of new compoundsto minimize magnetic anisotropy and hysteresis and newmanufacturing techniques to produce Terfenol-D thin filmsefficiently (9). Suhstantial advances have been achieved inthe quaternary compounds Terfenol-DH, which are pro-duced hy substituting bolmium for terbium and dyspro-sium (10). In addition, new manufacturing tecbniques areenabling the production of multilayered driver rods wbicbwill lead to reduced dynamic losses, thus facilitating op-eration over a broad frequency spectrum into the mega-hertz range. Ferromagnetic shape-memory alloys are an-other class of smart materials which hold much promisedue to the large strains that they can provide. The nickel-titanium alloy commercially known as Nitinol featureslarge recoverable strains of the order of 60,000x10 ^, butit suffers from inferior dynamic response. The possihilityof combining the desirable aspects of sbape memory withmagnetostriction through actuating an SMA in a magnetic

m.'orbit \ H

spin

Electron

Figure 2. In highly magnetostrictive materials, the spin momentniapin and orbital moment morbit a'"e strongly coupled. When thespin moment rotates to align with the extemal field H, the orbitalmoment rotates along with it and produces considerable latticedeformation.

field is currently being investigated. Promising candidatematerials are the Ni2MnGa system and the Fe-based In-vars, which exhibit, in principle, the desired characteris-tics. Further details on the Ni-Mn-Ga alloys can be foundin (11,12).

PHYSICAL ORIGIN OF MAGNETOSTRICTION

Magnetic coupling within atoms can be of two forms, spin-spin and spin—orhit interactions. In ferromagnetic materi-als, the spin-spin coupling that keeps neighboring spinsparallel or antiparallel to one another within domains canbe very strong. However, this exchange energy is isotropicbecause it depends only on the angle between adjacentspins, not on the direction of the spins relative to the crys-tal lattice.

Magnetostriction is due mainly to spin-orhit coupling,which refers to a kind of interaction between the spin andorbital motion of each electron. This type of coupling isalso responsible for crystal anisotropy. Referring to Fig. 2,when a magnetic field is applied and an electron spin triesto align with it, the orbit of that electron also tends to bereoriented. But because the orbit is strongly coupled totbe crystal lattice, the orbit resists the rotation of the spinaxis. Thus, the energy required to rotate the spin systemof a domain away from the preferred orientations is theenergy required to overcome spin-orbit coupling. Spin-orhit coupling is weak in most ferromagnetic materials, asevidenced by the fact that a moderate field of a few thou-sand kiloamperes per meter suffices to rotate the spins.Spin-orbit coupling in rare-earth metals is much strongerby about an order of magnitude. When a magnetic fieldrotates the spins, the orbital moments rotate, and consid-erable distortion, and hence magnetostriction, results (13).

MATERIAL BEHAVIOR

Magnetic Anisotropy

Magnetic anisotropy refers to the dependence of magneticproperties on tbe direction in which they are measured.It can be of several kinds, including crystal, stress, shape,

MAGNETOSTRlCTiVE MATERIALS 603

and exchange anisotropy. Of tbese, hoWever, only crystalanisotropy is intrinsic to the material, whereas tbe othertypes are externally induced.

In crystalline materials, the magnetic moments do notrotate freely in response to applied fields, but ratherthey tend to point in preferred crystal!ographie directions.This phenomenon is called magnetocrystalline (or crystal)anisotropy, and the associated anisotropy energy is thatrequired to rotate the magnetic moments away from tlieirpreferred direction. Crystal anisotropy energy and linearmagnetostriction are closely related. If anisotropy is in-dependent of the state of strain, there will be no linearmagnetostriction (14). In rare-earth elements, forinstance,large strains are a direct consequence of tbe huge straindependence of magnetic anisotropy (8). Under tbe actionof a magnetic field, measurable strains result from tbe de-formations that the crystal lattice undergoes to minimizethe energy state of the material.

Wben a sinusoidal magnetic field is applied to a ma-terial that has sufficiently large anisotropy, tbe result-ing magnetization curve is not smooth due to tbe pres-ence of magnetic moment "jumping." For example. Fig. ̂ ta,bshows the magnetization and magnetostriction of the alloyTbo,67Dyo33. which has substantial magnetic anisotropy.The discontinuity in botb curves near a field value of40 kA/m occurs because the magnetic moments abruptlyenter or leave low energy directions. Elements that have

3 -

2 -

1 -

0 -

1 -

2 -

3 -

6 -

4 -

2 -

(a)

(b)

1

/

t

1

I

(0 '

J(d)

1 V

1

_,

/

-160 -80 0 80 -80 80 1 EiO

Applied magnetic field (kA/m)

Figure 3. (a,b) Magnetization and magnetostriction jumpH inTbo 67 Dyo 33, a material that has large anisotropy. (c), (d) The samemeasurements are much smoother in a material that has near zeroanisotropy such as Tho.GDyo.4 (36). ,

604 MAGNETOSTRICTIVE MATERIALS

Figure 4. Crystallographic orientations in monolithic Terfenol-D. The square brackets represent the indexes of particular direc-tions such as the edges of a cube: [100], [0101, [001], [100], [010],and [001], in which 1 denotes - 1 . The entire set of directions isdesignated by any one direction in angular brackets, for instance,< 100>. Finally, planes of a form are designated by rounded brack-ets, such as the six faces of a cube: (100), (010), (001), (100), (010),and (001).

Opposite anisotropies are often alloyed together to re-duce the jumping and associated nonlinearities in materialbebavior. Such a material is shown in Fig. 3c,d. In this case,the same system but in a different composition (Tho.6Dyo4)exhibits a much smoother response to the applied field.

Accurate models for crystal anisotropy and its relation-ship to the magnetization process exist for simple cases ofcubic and hexagonal crystals (15,16), hut models of com-plex crystal structures often rely on simplifying assump-tions that reduce tbe problem to the simpler cases. Forinstance, it is often useful to assume operating regimesin wbich stress anisotropy dominates crystal anisotropy,thus enabling the modeling of highly complex cases suchas that of Terfenol-D whose crystals are grown in dendritictwin sheets oriented in the [1121 direction, as shown inFig. 4 and discussed in (1). Terfenol-D has a large and pos-itive magnetostrictive coefficient of Xni = -1-1.600 x 10"^,so a compressive stress applied along the (112) directionproduces a significant decrease in the internal energy ofthe crystal at right angles to the applied stress. On theother hand, although the anisotropy coefficient of Terfenol-D varies significantly, depending on temperature and sto-icbiometry (Ki = - 4 to -50 kj/m^ [3,17]), it is sufficientlylarge to resist such energy changes by favoring alignmentin the directions. Then, it is inferred tbat a suf-ficiently large compressive stress will raise the elasticenergy above tbat of the crystal anisotropy, shifting tbe

preferred orientation of domains to the magneticeasy axes that are perpendicular to the fll2] direction.Under such compressive stress, the population densityin these two orientations increases, and a magnetic fieldapplied in the [112] direction produces nearly isotropic 90"rotations because the energy wells of crystal anisotropyhave been effectively removed from the path of the ro-tations. In addition, under compression, as large popula-tions of magnetic moments align normally to the stressdirection, the demagnetized length decreases to a mini-mum, and the saturation magnetostrictive potential in-creases to a maximum. The 90 rotations subsequentlyprovide the maximum possible magnetostrictions. To sum-marize, in materials that have positive magnetostrictionslike Terfenol-D, the stress anisotropy generated by com-pression effectively improves tbe magnetoelastic statetbat leads to enhanced magnetostrictions. The manner inwhich tbis is implemented in transducer applications isdiscussed later. In nickel, wbicb has a negative magne-tostrictive coefficient, the effect is reversed, and enhancedmagnetoelasticity is ohtained from tensile stresses. Fur-ther details regarding crystal anisotropy can he found in(18-20).

Domain Processes and Hysteresis

The changes in magnetization that result from an appliedmagnetic field can he either reversible or irreversible. Re-versible changes in magnetization are energetically con-servative and occur for small field increments in which thematerial can return to the original magnetic state uponremoving the field. Irreversihle magnetizations are dissi-pative because external restoring forces are needed to re-turn the magnetism to its original state, for example, whenlarge fields are applied. In applications, both types of mech-anisms contribute to tbe magnetization process. Magneti-zation, eitber reversible or irreversihle, can be explained byconsidering two related mechanisms: the rotation of mag-netic moments and the movement of domain walls. Thepresence of domain walls lies in the domain structure char-acteristic of ferromagnetic materials below their magneticphase transition temperature or Curie temperature, 7J (seeTahle 1 for values of 7̂ ; for several magnetostrictive mate-rials). When a ferromagnetic material is cooled below itsCurie temperature, tbe magnetic moments become orderedacross volumes, called domains, that contain large num-bers of atoms. Tbe domain structure can he observed undera microscope, and it typically consists of lO'^-lO^^ atomsper domain. The transition regions between neighboringdomains are called domain walls. All of the moments ofeach domain are aligned parallel, producing a spontaneousmagnetization M^, but witbout a field, the direction of Msvaries from domain to domain, so that the bulk magneti-zation in the material averages zero. This is illustrated bytbe randomly oriented regions of Fig. 5a.

When a small magnetic Held H is applied, as depictedin Fig. 5b, domains oriented favorably to the field grow atthe expense of the remaining domains, and the main mag-netization mechanism is domain wall motion. As the fieldis increased (see Fig. 5c), entire domains rotate to align

MAGNETOSTRICTIVE MATERIALS 605

Table 1. Magnetoelastic Properties of Some Magnetostrictive Materials

Material

FeNiCo50% Co-50% Fe50% Ni-50% FeTbFe2TbDyTerfenol-DTbo,6Dyo,4Metglas 2605SC

-14(8)-50 (14)-93(14)

87(2)19(2)

2630 (8)3000 (-196^0 (36)6000(-196"C)(36)

1620 (8)6000 (-196^0) (36)

60 (36)

p (g/cm^)

7.88(14)8.9(14)8.9 (14)8.25 (8)

9.1(14)8.33 (14)8.56(14)

9.25

7.32 (2)

£t(T)

2.15(14)0.61(14)1.79(14)2.45 (76)1.60 (76)

1.1 (2)

1.0

1.65 (76)

TcC'C)

770 (14)358(14)

1120(14)500(14)500(14)423 (8)

^ 8 ( 1 3 )-184(1)380(76)

370(2)

E (GPa)

285(14)210(1)210(1)

55.7(1)61.4(1)110(77)

25-200(2)

k

0.31(8)

0.35 (8)

0.35 (8)

0.77 (78)

0.92 (1)

"Unless otherwise specified, all measurements were performed at room temperature.

with the easy [111] axis. This produces a burst region inthe magnetization versus field (M~H) and strain versusfield {e-H) curves by virtue of which small field changesproduce large magnetization or strain changes. In the fi-nal stage shown in Fig. 5d, the material acts as a single do-main as magnetic moments rotate coherently from the easyaxis to the direction of the field. This produces saturation ofthe magnetization. Typical magnetization and strain loopsshown in Fig. 6 illustrate the burst region and saturationeffects. From a design perspective, magnetic biasing de-scribed later is used to center operation in the burst regionfor optimum performance.

For low magnetic field levels, partial excursions in theM-H or F-H curve are observed that are approximatelylinear. However, hysteresis is always present, particularlywhen the materials are employed at high field levels such

as those of Fig. 6. The hysteresis can be attributed to the ir-reversible impediment to domain motion by pinning sites,such as when domain walls move across twin boundariesin Terfenol-D. Modeling hysteresis and nonlinear behav-ior is currently a focal point in designing and controllingmagnetostrictive materials. Extensive details on the topicof ferromagnetic hysteresis can be found in (14,21,22).

Material Properties

Strains are generated by magnetostrictive materials whenmagnetic moments rotate to align with an applied field.This phenomenon is governed by an energy transductionprocess known as magnetomechanical coupling that is in-trinsically bidirectional and that facilitates both actuat-ing and sensing mechanisms in a material. From a design

H H

Figure 5. Domain processes in the (110) plane of single crystal Terfenol-D under the application ofa field H along the [112] axis: (a) demagnetized specimen, (b) partial magnetization by domain-wallmovement, (c) from partial magnetization j-o the knee of tbe magnetization curve by irreversibledomain magnetization rotation into the [111] axis, and (d) from tbe knee of the magnetization curveto tecbnical saturation by reversible (coherent) rotation to tbe [112] axis (21).

606 MAGNETOSTRICTIVE MATERIALS

(a) 1

0.8

0.6

0.4

0.2

0

-0.2

-0,4

-0,6

-0,8

-1

1 1

1 1

1 1 1 1

1 1 ! 1

1 1

1 1

1 1 1 1

-1 -0,8 -0.6 -0,4 -0,2 0 0,2 0,4 0.6 0.8 1

H(A/m) x iO"

(b)

-1 -0.8 -0.6 -0.4 -0,2 0 0.2 0,4 0.6 0,8 1H (A/m) X 10"

Figure 6. Relative magnetization MjM^ and total strain ^ as afunction of magnetic field /f in a magnetostrictive material,

standpoint, the linear coupling coefficient k that quanti-fies the conversion efficiency between mechanical and elas-tic energies must be close to unity. Significant magneticmoment rotation occurs only wben a domain structure ispresent, that is to say, in the ferromagnetic state belowthe Curie temperature %. Hence, the material must bedesigned so that its Curie temperature is well above theoperating temperature range. In smart structure systems,large forces are often involved tbat the magnetostrictivematerial must support. The stiffness of the material isquantified by tbe elastic modulus E. Tbe material mustbave a large value of £̂ to support large forces. Finally, themagnetostrictive material must feature a large saturationmagnetization Mg (or, equivalently, a large saturation in-duction B^), and the magnetic anisotropy must be small.

Sbown in Table 1 is a list of nominal properties forseveral magnetostrictive materials of interest. Note thatthe magnetomechanical coupling responsihle for diversematerial properties is a highly complex function that de-pends on quantities such as magnetic field, stress, tem-perature, and frequency. These quantities are collectivelyknown as "operating conditions" and typically vary duringdevice operation. It has been demonstrated tbat small vari-ations in operating conditions often produce large cbanges

in material properties (23). Efficient transducer designrequires accurately assessing how material propertiesbehave under varying operating conditions.

LINEAR MAGNETOSTRICTION

Linear or Joule magnetostriction pertains to the strainproduced in the field direction and is the most commonlyused magnetostrictive effect. Because linear magnetostric-tion occurs at constant volume, there must he a transversestrain of sign opposite to that of the linear magnetostric-tion.

Isotropic Spontaneous Magnetostriction

It was mentioned earlier that when a ferromagnetic mate-rial is cooled through its Curie temperature, a transitionfrom paramagnetism to ferromagnetism takes place, andmagnetic moments become ordered giving rise to sponta-neous magnetization M̂ within domains. This process isalso accompanied by a strain which is known as sponta-neous magnetostriction ko. It is possible to derive a use-ful relationship between ko and saturation magnetostric-tion A,g. To that end, we consider an isotropic materialin the disordered state above 7̂ ., which is therefore mod-eled by spherical volumes, as shown in Fig. 7a. As thematerial is cooled below 7"̂ spontaneous magnetizationMg is generated within magnetic domains along with thecorresponding spontaneous magnetostriction XQ. The do-mains are represented in Fig. 7h by ellipsoids tbat bavespontaneous strain e. Because the material is isotropic, tbemagnetic domains are oriented randomly; each bears anangle 8 with respect to the direction of measurement. Netmagnetization is consequently zero, and the length in the

(b)

(c)

Figure 7. Schematic diagram illustrating the magnetostrictionof a ferromagnetic material: (a) paramagnetic state above 2J; (b)after it has been cooled tbrough %; and (c) after it has been broughtto saturation by a field H.

MAGNETOSTRICTIVE MATERIALS 607

direction of interest is given by (13)

e(e) = e cos^e. CD

Then, the average domain deformation at the onset of spon-taneous magnetostriction can be obtained by integration inall possible directions,

J-njie cos^ 6 sin 0 de = - .

Spontaneous magnetostriction Xo ia homogeneous in all di-rections, so that the material has changed its dimensionsbut not its shape. When a magnetic field is applied, the do-mains rotate and become aligned either parallel to the fieldor perpendicular to it, depending on whether the materialexhibits positive or negative magnetostriction. Assumingpositive magnetostriction, the domains will rotate into thefield direction, as depicted in Fig. 7c. Near saturation, thematerial will be a single domain, and the total strain willbe e. Then, the total available saturation magnetostrictionis given by the difference between e and XQ,

2(2)

This expression provides a method of measuring the spon-taneous strain XQ by measuring XB- Methods to determineXs are discussed next.

Saturation Magnetostriction

Assuming again for simplicity that the medium is isotropic,saturation magnetostriction at an angle 0 to the directionof the field is given by (13)

(3)

where Xg(9) is the saturation magnetostriction at an angle 0to the field and X^ is the saturation magnetostriction alongthe direction of magnetization.

The saturation magnetostriction is then calculated fromthe difference between the maximum magnetostrictionwhen the field is parallel to a given direction {XB\\) and thatwhen the field is perpendicular to the given direction (Xs±).Substituting 9 = 0 and 0 = 90^ in Eq. (3) gives

1 3+ — Xs — -^ (4)

which defines Xg independently of the demagnetized state.Magnetostriction data from Clark (8) taken from poly-

crystalline Tb^Dyi-xFey samples are reproduced in Fig. 8.The data points correspond to Xs\\ — Xs_i at room temper-ature and field values of H = 10 kOe (0.8 MA/m) andH=25 kOe (2 MA/m). Near x = 0.3, the magnetostric-tive curve shows a peak in accordance with the near zeromagnetic anisotropy observed at this composition. Fromthe magnetostrictive value at the peak, about 1600 x 10"^,

3000

2000

3

1000

.] I ITb Feg 0.2 0.4 0.6 0.8 Dy Fe2

1-x

Figure 8. Magnetostriction of polycrystalline TbxDyi_jiFe2 atroom temperature (8).

Eq. (4) gives Xg = 1000 x 10 ^ which is a widely employedvalue for the saturation magnetostriction of Terfenol-D.

Anisotropy is present to some degree in all magneticmaterials, and therefore, the saturation magnetostrictionneeds to be defined relative to the axis along which themagnetization lies. One exception is nickel, whose mag-netostriction is almost isotropic (see Table 2). Recognizingthat there are two independent magnetostriction constantsXioo and A,in for cubic materials, the saturation majjne-tostriction, assuming a single crystal, single domain ma-terial is given by a generalization of Eq. (3) for isotropicmaterials:

+ 3 X

+(5)

where Xioo and Am are the saturation magnetostrictionsalong the and axes of the crystal. Cosines u;;

Table 2. Magnetostrictive Coefficientsof Cubic Crystal Materials

Material

NickelIronTerfenol-D

-462190

-24-21

1600

608 MACNETOSTRICTIVE MATERIALS

(i = 1. 2, 3) define the direction along which the magneticmoments are saturated, and cosines j6, define the direc-tion in which the saturation magnetization is measured.The saturation magnetostriction in the field direction isobtained by using ai = ft in Eq. (5), which leads to

(6)

Note that Eqs. (5) and (6) apply only to single domain ma-terials. In the saturated state, the whole specimen consistsof a single domain whose magnetization Afg is aligned par-allel to the applied field. However, when a domain struc-ture is present such as in polycrystals, the magnetostric-tion can be calculated only by averaging the effects, unlessthe domain structure is known specifically. Note that dif-ferent domain configurations can give the same bulk mag-netization and different magnetostrictions (see Fig. 9). So,assuming that there is no preferred grain orientation,Eq. (6) simplifies further and becomes

— 2A.B — -

Extensive magnetostriction data on the R-Fe2 compoundscan be found in (8), and calculations of X^ in differentcrystallographic structures such as cubic, hexagonal, andpolycrystalline can be found in (2,13,16,21).

Magnetostriction below Saturation

Although saturation magnetostriction Xg can be deter-mined by employing the methods previously discussed,magnetostriction between tbe demagnetized state andsaturation is structure sensitive, so general constitutive

Figure 9. Demagnetized specimen featuring a 180° domain wallin the (a) horizontal or (b) vertical direction. The length of the spec-imen is different in either case, even though the magnetization isthe same.

relationships for magnetostriction are not feasible. How-ever, an explicit solution exists when strains are due pri-marily to 90' domain rotations. In practice, these rotationsoccur in (1) a single crystal that has uniaxial anisotropy inwhich the field is applied in a direction perpendicular to theeasy axis or (2) a polycrystalline material in which the mag-netic moments have been completely aligned in a directionperpendicular to the applied field, such as Terfenol-D un-der extreme compression or nickel under tension. The lat-ter implies that perpendicular stress energy is sufficient todominate crystal anisotropy, as discussed earlier. For thatregime, combining Eqs. (1) and Eq. (2) gives

X= -XB COS*' e. C7)

where Q is the angle between the M^ vectors and the fielddirection. Recognizing that the bulk magnetization in thefield direction is given by M = MB COS0, Eq. (7) becomes

Af(8)

which provides a quadratic relationship between magneti-zation and magnetostriction. It has been shown that thisexpression is sufficiently accurate in a broad range of trans-ducer regimes in which high mechanical preloads are em-ployed to optimize transducer performance (.24). A gener-alized version of this equation has been given in (25), andmore elaborate models of magnetostrictive hysteresis havebeen presented in (19,26—28). Additional effects such asstress dependences have been also considered (25,29). Fi-nally, the dependence of the magnetostriction of the R-Fe2compounds on temperature has been discussed in (8).

OTHER MAGNETOSTRICTIVE EFFECTS

Linear magnetostriction is just one of several manifesta-tions of a more general phenomenon, the coupling betweenthe magnetic and elastic states in a material. These ef-fects are briefly discussed following and are summarized inTable 3.

Villari Effect

The Villari effect, also known as the magnetomechanicaleffect, are the changes in magnetization that a magne-tostrictive material undergoes when subjected to an ap-plied uniaxial stress. This effect pertains to the trans-duction of energy fTom the elastic to the magnetic stateand is inverse of Joule magnetostriction. Furthermore, theVillari effect exhibits many of the attributes of the directmagnetostrictive effect inasmuch as its physical origin alsolies in magnetoelastic coupling. The Villari effect has beenthe object of much study, given its relevance in applicationssuch as nondestructive evaluation and sensing. Extensivetheoretical and experimental details can be found in (25).The effect of stress on magnetostrictive materials in par-ticular has been discussed in (30).

MACNETOSTRICTrVE MATERIALS 609

Table 3. Magnetostrictive Effects

Direct Effects Inverse EffectsJoule magnetostrictionChange in sample dimensions in the direction of the applied

fieldAE effectMagnetoelastic contrihution to magnetocrystalline anisotropyWiedemann effectTorque induced by helical anisotropyMagnetovolume effectVolume change due to magnetization (most evident near the

Curie temperature)

Villari effectChange in magnetization due to applied stress

Magnetically induced changes in elasticityMatteuci effectHelical anisotropy and emf induced hy torqueNagaoka-Honda effectChange in the magnetic state due to a change in volume

A f Effect

The elasticity of magnetostrictive materials is composedof two separate but related attributes, the conventionalstress-strain elasticity tbat arises from interatomic forcesand the magnetoelastic contribution due to the rotationof magnetic moments and tbe ensuing strain tbat occurwben a stress is applied. Tbe latter contribution, knownas tbe A E effect, is quantified by AE = {E^ - Eo)/Eo,wbere EQ is tbe minimum elastic modulus and E^ istbe elastic modulus at magnetic saturation. Because thestrain produced by magnetic moment rotation adds to thenon-magnetic strain [see Eq. (9)1, tbe material becomessofter when the moments are free to rotate. This is illus-trated in Fig. 10. Note tbat the material becomes increas-ingly stiff as saturation is approached and magnetic mo-ment mobility decreases. Tbe AE effect is small in nickel(AE = 0.06) but is quite large in Terfenol-D (AE up to5) and certain transverse-field annealed Fe8iBi3.5Si3 5C2(Metglas 2605SC) amorphous ribbons (A^^IO) . TbeAE effect of Terfenol-D can be advantageously employedin tunable vibration absorbers and broadband sonarsystems (31).

140

120 -

re0-O

lulu

s

.o

(SLU

100

80

60

40

20 ?

-

1

7MPa14MPa21 MPa28 MPa

1

1 ^

1

40

Applied bias field

80 120

Figure 10. Magnetoelastic modulus of Tbo3Dyo.7Fe2 undervarious stresses (79).

Wiedemann Effect '

A current-carrying ferromagnetic or amorpbous wire pro-duces a circular magnetic field in a plane perpendicularto the wire, and the moments align predominantly in tbecircumferential direction. When an axial magnetic field isapplied, some of tbe moments align belically and createa belical magnetic field. Tbe twist observed in tbe wireis called tbe Wiedemann effect. Tbe inverse Wiedemanneffect, known as the Matteuci effect, is the cbange in ax-ial magnetization of a current-carrying wire wben it istwisted. Further details can be found in (2).

Magnetovolume Effect

Tbe volume of a magnetostrictive material remains vir-tually uncbanged during normal operation, but in cer1;ainextreme regimes, tbe volume of tbe material may cbangein response to magnetic fields. Tbis anomalous volumecbange is called tbe volimie magnetostriction or Barret ef-fect. Tbe effect bas little applicability in smart structuresystems. For instance, tbe magnetostriction curve of nickelrapidly reacbes -35 x 10"^ at only 10 kA/m, but tbe frac-tional volume cbange is only 0.1 x 10"^ in a mucb largerfield of 80 kA/m. In tbe alloy Invar (36% nickel-64% iron),tbe fractional volume cbange at tbe Curie temperature,wbicb is slightly above room temperature, compensatesfor tbe intrinsic tbermal expansion and gives a compoundtbat has nearly zero tbermal expansion at room tempiira-ture. Tbe inverse of tbe Barret effect, the Nagaoka-Hondaeffect, is tbe change in magnetic state caused by a voliunecbange (2,14).

MAGNETOSTRICTIVE TRANSDUCERS

One advantage of magnetostrictive transducers over othertypes of transducers is tbat tbey can be driven by con-ventional low impedance amplifiers, particularly at fre-quencies well below resonance; in tbis case, the lowimpedance of a magnetostrictive transducer means thatdriving voltages can be low. This can prove useful in medi-cal applications and in general can greatly simplify ampli-fier design. Figure 11 shows the measured complex elec-trical impedance frequency response function Z^^ = V/Iof a Terfenol-D transducer designed following the generic

610 MAGNETOSTRICTIVE MATERIALS

100 Prestress bolt Permanent magnet Solenoid Compression spring

-100

0 1000 2000 3000 4000 5000 6000Frequency (Hz)

(b) 200 100

-100

1000 2000 3000 4000 5000 6000

Frequency(Hz)

Figure 11. Total electrical impedance Zee versus frequency, ex-pressed as magnitude and phase: (a) bias condition of 5.2 MPa,24 kA/m (0,75 ksi, 300 Oe), and varied ac drive levels; (b) constantac drive level of 8 kA/m (100 Oe) and varied bias conditions (79).

configuration indicated in Fig. 12 (32,33). This transducerconsists of a cylindrical magnetostrictive rod, a surround-ing copper-wire solenoid, a preload mechanism that con-sists of a bolt and a spring washer, magnetic couplers, anda barrel-like permanent magnet that provides bias magne-tization. Specific design details depend on the particularsmart structure application; however, this configurationdepicts the basic components needed to extract maximumperformance from a magnetostrictive material.

Because magnetostriction is produced by the rotation ofmagnetic moments, a magnetostrictive transducer drivenby an ac magnetic field vibrates at twice the drive fre-quency, and the motion occurs in only one direction. Thisis illustrated in Fig. 13, where the solid lines representthe unbiased input and corresponding strain output. Thedashed lines demonstrate the performance improvementsachieved by applying a magnetic bias. In the biased regime,the frequency of the input is preserved, the output is bidi-rectional, and the ratio of output per input is substan-tially larger. To center operation accurately around the

Magnetic coupler Magnetostrictive rod Displacement plunger

Figure 12. Cross section of a typical magnetostrictive transducer.

desired bias point, a permanent magnet is often employedin combination with a static field generated by passing adc current through the solenoid. Note that exclusive per-manent magnet biasing has the advantage of substantialpower savings, but it has the disadvantage of added bulkand weight. Conversely, dc currents produce considerablepower losses through ohmic beating but facilitate savingsin bulk and weight. Magnetic biasing can be alternativelyprovided by magnets located in series with the rod or rods;this design is known as a stacked-magnet configuration.The stacked-magnet configuration can improve the magne-tomechanical coupling up to 5% for large rods (L > 20 cm,D > 2.5 cm) compared to the barrel-magnet configuration.However, collateral problems such as saturation effectsand resonance frequency shifls are common in stacked-magnet designs. Carefully designed transducers must pro-vide efficient magnetic flux closure within the circuitformed by the rod itself, the couplers, and the permanentmagnets.

Strain

Outputs

Unbiased

Biased

Inputs

Figure 13. Effect of magnetic bias on the strain produced by amagnetostrictive transducer.

MACNETOSTRICTIVE MATERIALS 611

Finally, altbough modem magnetostrictive materialssucb as Terfenol-D are manufactured so tbat tbeir mag-netic moments are nearly perpendicular to the rod axis,a static stress (mechanical preload) is nevertheless, re-quired to achieve full alignment of all of the moments.The moments of a mechanically free rod are aligned ran-domly, and the rod produces only about half of its meix-imum magnetostriction because the moments initiallyaligned with tbe rod axis do not contribute to tbe mag-netostriction. Furthermore, tbe stress anisotropy gener-ated by the static compression (or tension for materialsof negative magnetostriction) enhances tbe overall mag-netoelastic state, as described previously. Note tbat in de-signs tbat employ linear wasbers for preloading, the stressin tbe magnetostrictive rod can vary significantly rela-tive to the nominal preload during dynamic transduceroperation. By virtue of tbe magnetomechanical coupling,tbis can bave a profound impact on tbe performance of themagnetostrictive transducer and driving electronics by af-fecting tbe magnetic state and, through it, the electricalregime (see Fig. 11). The effects of mechanical preload andmagnetic bias on tbe performance of a Terfenol-D trans-ducer have been studied in (34). A second reason for em-ploying a mechanical preload is to avoid operating tbe rodin tension, particularly wben driving brittle materials suchas Terfenol-D (fit ^ 28 MPa, a, = 700 MPa) at or near me-cbanical resonance.

Actuator Applications

Tbe number of actuator applications based on magne-tostrictive materials, mainly Terfenol-D, is continuouslyincreasing as a consequence of tbe bigb energy density,higb force, broad frequency bandwidtb, and fast responsethat tbese materials provide. Even tbougb tbe cost ofTerfenol-D is bigb at present, tbe range of applications islikely to continue increasing as manufacturing tecbniquesare perfected and prices decline. Actuators designed ac-cording to tbe configuration shown in Fig. 12 have been em-ployed in tbese applications: sonar, cbatter control for bor-ing tools, bigb-precision micropositioning, borehole seismicsources, geological tomography, bydraulic valves for fuelinjection systems, deformable mirrors, bydraulic pumps,bone-conduction bearing aids, exoskeletal telemanipula-tors, self-sensing actuators, degassing in manufacturingprocesses sucb as rubber vulcanization, and industrial ul-trasonic cleaning. Four main application subgroups of cur-rent transducer designs are discussed here: sonar trans-ducers, linear motors, rotational motors, and bybrid smartmaterial transducers. The reader is directed to (1,2) formore complete details.

Sonar Transducers. Efficient sonar transducers mustproduce high mecbanical power at low frequencies and of-ten have the additional constraint that a broad frequencybandwidth or equivalently, a low quality factor Q, must beattained. Although nickel was widely employed in sonarapplications during World War II, it has a low magneto-mechanical coupling coefficient of A = 0.30 which typi-cally demands a bigb Q to acbieve good efficiencies. In

contrast, tbe newer giantmagnetostrictive materials bavemuch higher coupling coefficients of more than k ~ 0.70which makes it possible to operate the transducer at lowQ and attain high power output simultaneously. For ex-ample, a Terfenol-D Tonpilz transducer similar to that de-picted in Fig. 14a can produce a bandwidtb of 200 Hz at aresonance frequency of 2 kHz (Q = 10) and a source levelof 200 dB ref 1 /iPa at 1 m (35). Another Terfenol-D trans-ducer reportedly produces a maximum output of 206 dB

iHousing

-i=i- Nodal support

Tail mass Soienoid Magnetic coupler Tube Head mass

Radiatingsurfaces

Figure 14. Magnetostrictive sonar transducers: (a) Tonpilz,(b) flextensional, and (c) square ring.

612 MAGNETOSTRICTIVE MATERIALS

ref. 1 /iPa at 1 m and operates across a broad usable band-width of 5-50 kHz (36). Other designs employ the linearmotion of cylindrical magnetostrictive rods to flex a sur-rounding shell or to induce radial vibrations in a tube orring, as shown in Fig. 14b,c. Furtber details and referencesare provided in (37).

Linear motors. Direct coupling between the load and themagnetostrictive element in Fig. 12 implies tbat the netload displacement is limited by magnetostriction. For in-stance, an 11.4-cm Terfenol-D actuator provides maximumdisplacements of about 0.2 mm. This displacement level issufficient for many vibration control applications, but cer-tain applications such as flow control valves or aircrafl flappositioners typically require mucb larger strokes.

The fact tbat Joule magnetostriction takes place at con-stant volume is employed in tbe Kiesewetter motor todisplace loads beyond tbe maximum strain normallyacbievable by a Terfenol-D rod. Tbis motor (38) consistsof a cylindrical Terfenol-D rod tbat fits snugly inside a stiffstator tube wben no magnetic field is applied. Several shortcoils surround tbe stator to produce a magnetic field pro-file tbat sweeps along the Terfenol-D rod. When one of thecoils is energized, for instance, coil 1 in Fig. 15a, tbe sectionof rod directly exposed to the magnetic field elongates andshrinks. As tbe field is removed, the rod clamps itself againinside tbe stator but at a distance d to tbe left of the originalposition. As tbe remaining coils are energized sequentiallyand tbe magnetic field profile is swept, the rod moves ina direction opposite to tbe sweeping field. The direction ofmotion is changed by inverting the sequence in which tbecoils are energized. From a design perspective, tbe totaldisplacement is limited only by tbe lengtb of tbe Terfenol-D rod, wbereas tbe speed of motion is proportional to thesweeping frequency and the magnetostriction of tbe rod.Otber factors that affect the smoothness and speed of themotor are the number of traveling pulses, the spacing bet-ween excitatory coils, tbe stiffness of the Terfenol-D mate-rial, and skin effect degradation due to eddy currents. TheKiesewetter motor is self-locking when unpowered, whichis an important attribute for many robotic applications.

A proof-of-concept Kiesewetter motor presented in (39)produces 1000 N of force and 200 mm of useful stroke ata speed of 20 mm/s; it is intended for uses such as controlof coat weight and fiber distribution in the paper industryand valve operation and precision positioners for the ma-chine tool industry. An improved design presented in (40)addresses some of the technical problems of the Kiesewet-ter motor, particularly the degradation of fit between tbestator and tbe rod caused by wear and tbermal expansion.Furtbermore, this revised design enables rotary motion ina way that is otheiTvise impossible to achieve by using tbeoriginal Kiesewetter design.

Anotber variant of the incbworm principle is shown inFig. 15b. This motor consists of translating clamps, fixedclamps, pusber transducers, and a load shaft. By coordi-nating tbe clamping and unclamping actions of tbe clampswitb tbe action of the pushing transducers, it is possibleto induce bidirectional motion of the load shaft. The loadrating is limited by tbe frictional force between tbe clampsand tbe load shaft. Note tbat the incbworm principle can

H = 0

H Appliedto coil 1

Stator

Magnetostrictiverod

d ?

H Appliedto coil 2

H Appliedto coil 3

H Appliedto coil 4

H = 0

(b)Translatingclamps Fixed position

clamps

Loadshaft

Pusher transducers

Figure 15. (a)The Kiesewetter inchworm motor. Black rectanglesindicate energized coils; white rectangles indicate inactive coils.(b) Inchworm linear motor.

also be implemented by using other smart materials sucbas piezoelectric stacks (41) or a combination of piezoelectricand magnetostrictive elements, as sbown later.

Piezoelectric transducers are often preferred for ultra-sonic power generation in tbe megahertz range, but certainapplications in tbe low-ultrasonic range benefit from theruggedness and lack of depoling mechanisms of magne-tostrictive materials. For instance, nickel is extensivelyused in applications sucb as degassing liquids (20-50 kHz)

MAGNETOSTRICTIVE MATERIALS 613

Tertenoi-D Resonant Titanium Acoustic Tooitransducer support waveguide iiorn tip

Figure 16. Schematic diagram of an ultrasonic Terfenol-D deviceconsisting of a quarter-wave transducer coupled to a quarter-wavetitanium waveguide and a half-wave acoustic horn. Different tooltips can be used as needed.

and cleaning dental or jewelry pieces (more tban 50 kHz). Asurgical ultrasonic tool based on Terfenol-D was developedrecently that reportedly provides enhanced power and dis-placement output compared to existing piezoelectric tools;it is also lighter, more compact, and can deliver a 600-V,1-MHz signal to cauterize bleeds witbout affecting itssurgical function. In this device, illustrated in Fig. 16, alaminated quarter-wavelength Terfenol-D rod is coupledto a quarter-wavelength titanium waveguide that providesthe resonant subassembly to which a balf-wavelengtbacoustic bom is attacbed. Tbe acoustic born bas an am-plification factor from 15-30; tbus, it provides extremeaccelerations and energy concentration at the tip of thetool (42,43). Other current or potential uses for tbis trans-ducer design include industrial cleaning, sonic cell disrup-tion and sterilization, friction welding, and treatment ofdiverse cbemical and biological processes (1).

Rotational Motors. Smart material motors based on tbemagnetostrictive principle are potentially simpler andmore reliable tban conventional bydraulic or electromag-netic systems. The inchworm technique has been employedin a rotational motor that produces a torque of 3 Nm at aspeed of 0.5 rpm (44). Another inchworm type device alsoprovides a speed of 0.5 rpm but produces a very higb torqueof 12 Nm and precision microsteps of 800 /^rad (45). Despitethe great positional accuracy and high holding torques, thecurrent incbworm-type rotational motors tend to lack effi-ciency. Mucb of tbe efficiency limitation has been overcomein the resonant rotational motor proposed by Claeyssen etal. (46). Two linear Terfenol-D actuators are used to in-duce elliptical vibrations in a circular ring tbat acts asa stator and transmits tbe vibrations to rotational rotorspressed against tbe ring. The prototype reportedly pro-vides a maximum torque of 2 Nm at a maximum speed of17 rpm.

The field of ultrasonic rotational motors has arousedmucb research and commercial interest. Tbese motors areemployed in a wide range of applications from autofocusingcamera lenses to robotic manipulators. A rotational actua-tor developed by Akuta (44) employs Terfenol-D to achievea relatively bigh speed of 13.1 rpm and a maximum torque

Motion of tipof driving piece

Eiement A Element B

fTTTTTTTAFigure 17. Rotational ultrasonic motor (44).

of 0.29 Nm. As depicted in Fig. 17, tbis motor employs iwoTerfenol-D exciter rods to induce rotations in tbe sbaft.

Hybrid Magnetostrictive/Piezoelectric Devices. Giventheir technological interest, hybrid smart material actu-ators can be considered a separate class independently ofwhether tbey are intended for sonar, linear, or rotationalapplications. Because magnetostrictive materials are in-ductive and piezoelectric elements are capacitive, it is ad-vantageous to combine both types of materials in the samedevice, so tbat a resonant electric circuit is formed. Wliendriven at resonance, sucb a device bebaves like a purelyresistive load and only tbe energy tbat is effectively con-verted to mecbanical motion or lost to inner losses needsto be supplied externally. Tbis greatly simplifies amplifierdesign and belps to attain higb efficiencies.

Tbe bybrid device has been demonstrated tbat over-comes the difficulties involved in achieving motion atonly one end of a Tonpilz piston-type sonar transducer;it consists of a quarter-wavelength stack of piezoelectricNavy type I ceramic rings joined to a quarter-wavelengthTerfenol-D composite tube [see Fig. 18a and (47)]. Tbe in-herent 90' pbase sbifl between tbe magnetostrictive andpiezoelectric velocities in combination witb the quarter-wavelengtb design of the elements ensures addition at oneend and cancellation at tbe otber. Tbe device is mechani-cally unidirectional, but it becomes acoustically unidirec-tional only under array-baffled operation. The measuredfront-to-back pressure ratio is 5 dB for the device alone and15 dB under array-loaded conditions. Tbe concept of bybridpiezoelectric/magnetostrictive transduction bas also beenimplemented for linear incbworm motors (48,49) and rota-tional motors (50). For example, the prototype presentedin (48) has tbe configuration sbown in Fig. 15b, but theclamping is done by piezoelectric stacks, and the transla-tion is provided by Terfenol-D rods. Tbe intrinsic 90 pbaselag between tbe two types of elements provides naturaldrive timing for tbe incbworm, and tbe direction of motion

614 MAGNETOSTRICTr VE MATERIALS

(a) Preload rod Piston

Piezoelectriccomponent

Magnetostrictivecomponent

(b)Piezoelectricstack

Magnetostrictiverod

Magnetostrictiverod

Clamp

Figure 18. Hybrid magnetostrictive/piezoelectric transducers:(a) sonar projector (47); (b) rotational motor (50).

is easily reversed hy changing the magnetic hias on theTerfenol-D elements. This motor achieves a zero-load speedof 25.4 mm/s and a stall load of 115 N.

The hybrid magnetostrictive/piezoelectric rotationalmotor illustrated in Fig. 18h follows the proof-of-concepttransducer presented in (50). A piezoelectric stack clampsa piece of friction material onto the rotating disk, and twomagnetostrictive rods move the clamp tangentially to thedisk to produce rotational motion. As indicated hefore, thesequence of the motion is determined by the natural timingof the piezoelectric and magnetostrictive responses. Thedevice produces a speed of 4 rpm at excitatory voltagesfrom 30-40 V and frequencies from 650-750 Hz.

Sensor applications

Magnetostrictive materials are heing employed in a widevariety of sensor designs as evidenced by the growing num-her of publications and patents. In this overview, the termsensor is used in a broad sense to indicate the attributesof magnetostrictive materials that facilitate generation ofelectrical signals in response to mechanical excitations,such as force, strain, and torque, or magnetic excitationssuch as magnetic fields. By virtue of the magnetomechan-ical coupling, changes in the magnetoelastic state throughthese parameters (or a combination of them) produce mea-surable change in magnetization anisotropy. To completethe sensing mechanism, a pick-up coil is oflen wrapped

around the magnetostrictive material to detect magneti-zation changes; this effectively provides a mechanism forconversion of energy from magnetic to electrical regimes.The principle that links the magnetization with the volt-age V generated across a pick-up coil is the Faraday-Lenzlaw of electromagnetic induction:

dt

in which N and A are, respectively, the number of turnsand constant cross-sectional area of the coil and B is themagnetic induction that quantifies the magnetization statethrough the relationship B = HQ{H + M) (21). Alterna-tively, interferometric techniques can be employed to de-tect the changes in wave speed that occur when the magne-tostrictive material changes its properties in the presenceof external excitations, for instance, the stiffness changesassociated with the AE effect descrihed earlier.

An overview of sensor designs is presented next. Themain principles that enahle operation of the sensors areemphasized. The list is not comprehensive, but it showsthat a huge number of alternative designs can he de-vised hased on the fundamental operation principles pre-sented here. Further details can he found in the referencesprovided.

Torque sensors. Magnetostrictive noncontact torque me-ters have been devised hased on the principle that thetorque applied to a shaft generates stresses of oppositesign, -l-r and —r, oriented ±45' from the shaft axis. If theshaft is magnetostrictive or has a magnetostrictive amor-phous ribbon bonded to it, the magnetic properties alongthe directions of +r and —r change as discussed previ-ously. These properties can be measured either differen-tially by a set of perpendicular coils, as shown in Fig. 19a,or through a single Hall effect or similar magnetic field in-tensity sensor (51). This kind of sensor can be employed,for instance, in fiy-by-wire steering systems for the auto-motive and aerospace industries. Additional details andreferences can be found in (2).

Another class of noncontact torque meters relies on thechanges in permeability exhibited by a magnetostrictivematerial subjected to torsional stress. In particular, appli-cations that require less sensitivity can benefit from theelevated mechanical strength that magnetic steels or al-loys provide. One example is shown in Fig. 19h, where theworking torque on a drill hit is detected by two sensingcoils connected in series, one located over the flutes andthe other over the shank (the permeability of the shank isless sensitive to changes in torque than the flutes.) A coilprovides the ac magnetic field excitation, and the sensor'sproportional output is the differential voltage generated bythe sensing coils as the permeahility of the hit changes dueto the applied torque (52).

Deformational and Position Sensors. Transverse-field an-nealed magnetostrictive ribbons or wires make very sensi-tive strain gauges. A sensor of this kind has been madefrom strips of Metglas 2605SC transverse annealed for10 min in a 208 kA/m (2.6 kOe) magnetic field at 390X

MAGNETOSTRICTIVE MATERIALS 615

(a)

Figure 19. Magnetostrictive noncontact torque sensors: fa) Dif-ferential reading in directions oriented ±45^ from the shaft axisand (b) differential reading of the permeability changes experi-enced by a drill bit subjected to a torque.

and rapidly cooled in a saturation field (53). The sensorresponds to the changes in the permeability of the rib-bon, which by virtue of the magnetomechanica! couplingdepends in turn on the state of strain in the material.Defining a dimensionless gauge factor as the fractionalchange in the measured parameter (in this case perme-ability) divided by the change in strain, F = (Bii/dS)/fi,

Emitter/Receiverhead

Motion

Magnetostrictivewaveguide

Moving magnet

Damper

Figure 20. Magnetostrictive waveguide position sensor.

this sensor has an F value equal to about 250,000, whichcompares extraordinarily well with resistive strain gauges(F = 2) and semiconductor gauges (F = 250). One problemencountered in using this device is that normal thermalexpansion can saturate the sensor. This problem can beovercome by bonding the material using a highly viscousliquid, although this limits operation to ac regimes.

A position detector can be made by using a magne-tostrictive material as an acoustic waveguide. This device,shown in Fig. 20, consists of a permanent magnet that isconnected to the target and rides along the length of thewaveguide, an emitter/receiver head that sends and re-ceives either an acoustic or current pulse down the waveg-uide, and a damper that prevents unwanted wave reflec-tions. The sensor's operating principle is rather simple;the magnet interacts with the magnetostrictive waveguideand locally changes its material properties. These materialproperty changes can he detected in different ways. In oneversion, the stiffness discontinuity produced by the magnet{AE effect, see earlier) partially reflects an acoustic pulsesent by the emitter. In a second version, the emitter sendsa continuous current pulse down the waveguide that pro-duces a circumferential magnetic field that interacts withthe axial field from the magnet. The resulting helical fieldproduces a twist in the wire (Wiedemann effect) that trav-els back to the receiver head. In both versions, the transittimes of the original and reflected pulses provide a mea-sure of the location of the magnet along the waveguide.This sensor can be used for measuring fluid levels by con-necting the magnet to a float or for generic position sensingof up to 50 m at ±1 mm accuracy (2).

Magnetometers. If the magnetostriction of a given ma-terial is known as a function of magnetic field, the problem

616 MAGNETOSTRICTIVE MATERIALS

PiezoelectricForce

Magnetostrictive

{b) Amorphous ribbon Viscous fluid

Pick-up coil PZT

Figure 21. Hybrid magnetostrictive/piezoelectric magnetic fieldsensors. When a magnetic field is applied to one of these sensors,the magnetostrictive material strains, which either (a) generatesa voltage across the piezoelectric plate or (b) induces an emf ina surrounding pick-up coil that can he extracted from the alter-nating carrier emf produced as the piezoelectric plate resonates.

of measuring the magnetic field reduces to one of measur-ing length. The length can be measured by a laser inter-ferometer, optic fiber, strain gauge, capacitor, or anothercalibrated material such as a piezoelectric compound. Forexample, a very simple design consists of two slabs of mag-netostrictive and piezoelectric materials bonded together(Fig. 21a). When a magnetic field is applied to the magne-tostrictive material, it strains and induces a proportionalvoltage in the piezoelectric material. In another version,shown in Fig. 21h, a magnetometer is realized by bondinga field-annealed metallic glass ribbon onto a resonatingPZT plate by using a viscous fluid. An alternating voltageis applied to the PZT plate, which generates a longitudi-nal stress field. By using proper bonding techniques, thedynamic stress in the metallic ribbon is congruent withthat in the PZT, and the static component is filtered outby the viscous fluid. By virtue of the Villari effect, thesedynamic stresses create an oscillating electromotive force(emf) in the surrounding pick-up coil. When exposed tolow-frequency magnetic fields, a low-frequency emf is gen-erated in the coil that is extracted from the carrier emfby conventional phase sensitive detection techniques. Themeasured detection limit can reach 6.9 x lO*^ A/m at 1 Hz(54), which compares with that of fluxgate magnetometers.

Excitationcoii

Magnetostrictiveelements

Rigid endplate

Pick-upcoil

Rigid endplate

Force

Figure 22. Magnetostrictive force sensor based on the Villarieffect.

Another type of magnetometer consists of a magneto-strictive film bonded to an optic fiber. When the sensor isexposed to magnetic fields, the magnetostrictive materialdeforms and induces a deformation in the optic fiher. Thiscauses changes in the optical path length of laser beamsthat pass through the optic fiber and can he detected by aninterferometer (55). Highly sensitive metallic glass ribbonshave been employed in devices so designed that yield quasi-static resolutions from 1.6 x 10-^-8.0 x 10"^ A/m (56). Fi-nally, a diode laser interferometer has heen used to detectchanges in the length of a Terfenol-D rod that are producedwben a magnetic field is applied (57). A maximum sensitiv-ity of 160 X 10"'" A/m was achieved, although certain non-linear dependences were observed that make it critical tooperate the sensor within its optimum mechanical preloadrange.

Force Sensors. By employing the Villari effect, it is pos-sible to realize a simple and rugged force sensor fromeither crystal or amorphous magnetostrictive materials.The magnetostrictive attribute that provides the operat-ing principle for such a sensor is the dependence of magne-tization on the state of stress in a material. To illustrate,the design in Fig. 22 consists of two magnetostrictive ele-ments, one surrounded by an excitation coil and the othersurrounded by a pick-up coil, and two rigid end plates. Inone mode of operation, an ac voltage is applied to the ex-citation coil that generates a magnetic flux in the sensorand a corresponding voltage in the sensing coil. As a forceis applied, the magnetostriction in the elements producesa change in the magnetic flux that is detected as a pro-portional voltage change in the pick-up coil. In a secondmode of operation at constant flux, the excitation voltageis allowed to change to maintain a constant pick-up coiloutput voltage. The change in excitation voltage is thenrelated to the change in the applied force. Compared toconventional force sensors such as those based on straingauges, this sensor is simpler, more rugged, and requiressimpler electronics. A similar Villari effect sensor based onamorphous ribbons has been discussed in (58). Numerousother designs have heen discussed or patented, including

MAGNETOSTRICTIVE MATERIALS 617

percussion sensors, pressure sensors, and force sensorsbased on magnetoelastic strain gauges. The reader is di-rected to (2) for further details and references.

Transducer Models

Fundamental models of the performance of magnetostric-tive materials used in smari; structure systems areparticularly difficult to develop. The difficulty lies in thecoupling between regimes and the strong nonlinear de-pendence of material behavior on operating conditionsand the hysteresis inherent in the materials. Notwith-standing, models based on physical principles are neces-sary to optimize transducer design and control, particu-larly considering that first-principles models provide theability to scale the results in a sense that empirical mod-els typically do not. These include magnetization modelsbased on Preisacb, Stoner—Woblfarth, Jiles—Atherton, andmicromagnetic theories, as well as domain rotation andhigher order magnetostrictive models. However, compre-hensive models for designing and controlling integratedsmart structure systems must address the interaction bet-ween the magnetostrictive material's elastic, magnetic,thermal, and electrical regimes and the dynamics of theunderlying structure. This can include elastic dynamicsand also acoustics attributes. Following is an overview ofmodels that have been employed to design and control mag-netostrictive transducers. The reader is directed to the ref-erences for more comprehensive details on individual mod-eling techniques.

Piezomagnetic Constitutive Equations. Piezomagneticmodels analogous to those classically employed for piezo-ceramics can prove useful for low drive level applicationswhere hysteresis is minimal and behaviors are quasi-linear Neglecting thermal effects, the total strain e ofa magnetostrictive material includes two contributions:(1) the magnetostriction k produced by the rotation ofmagnetic moments as they align with externally appliedmagnetic fields and (2) a purely elastic component e = saof the kind found in conventional nonmagnetic materi-als. Analogously, the magnetic induction B consists oftwo contributions: (1) a magnetomechanical componentdependent on the stress and (2) the constant-stressmagnetic constitutive law B = jiH. From these considera-tions, the constitutive linearized equations that describemagnetostriction or piezomagnetism can he written indifferential form, as follows:

Ae = S"ACT

AS = d' Aa(9)

where F is the total strain in the magnetostrictive material,s^ is the compliance at constant field H, d and d* are thepiezomagnetic coefficients, a is the stress, B is the magneticinduction, and M" is the magnetic permeability at constantstress.

The ratio of fundamental constants k"^ =^d^ j {s^ii") forthis one-dimensional linearized case provides a formu-lation which has been of value in describing the mag-netomechanical coupling coefficient k of magnetostrictive

materials. This coupling coefficient provides a measure ofthe conversion efficiency hetween magnetic and mechani-cal energies. Specifically, the magnetomechanical couplingcoefficient squared represents the fraction of maximumstored magnetic energy that can be converted into elas-tic energy or conversely, the fraction of maximum storedelastic energy that can be converted into magnetic energy.It has been shown (59) that k can be expressed in terms ofsuitable internal energies,

k =

in which Um^ = {\/2)Hd'n is the magnetic energy dueto elastic energy, Ue = (1/2) sa^ is the elastic internal en-ergy and t/m = (l/2)/i /f̂ is the magnetic internal energy.Note that these expressions for k are based on the intrin-sic assumption of piezomagnetic reciprocity, that is, d = d'and ^ne = Uem = (l/2)dHa. In that sense, these expres-sions must be employed strictly within the linear operatingregimes in which the reciprocity assumption is sufficientlyaccurate. Typical values of the coupling constant are pro-vided in Table 1. Further details can be found in (1,8).

The piezomagnetic model given by Eq. (9) has been aug-mented by adding saturation phenomena, temperature de-pendences, and the quadratic relationship between themagnetization and free strains given by Eq. (8), This higherorder anhysteretic model has been described elsewhere (4).Like the original formulation from which it derives, thisaugmented model has the advantage of simplicity in ad-dition to adding certain nonlinear features. In this model,however, complete nonlinear phenomena or hysteretic ef-fects can be addressed only by using complex model pa-rameters. Furthermore, this model addresses materialattributes primarily but disregards important transducereffects such as the electrical and dynamic regimes. Theseeffects have been addressed to some degree by coupling thepiezomagnetic equations (9) with transducer models suchas the linearized canonical equations for electromechanicaltransducers.

(10)

that describe the behavior of a "black box" analog of a trans-ducer system that consists of two coupled electrical and me-chanical regimes (60,61). In these equations and Fig. 23,

Transducer

Figure 23. Schematic representation of an electromechanicaltransducer. i

618 MACNETOSTRICTiVE MATERIALS

V and / are the voltage and current in the coil, Z^ is theblocked electrical impedance (electrical impedance that isobserved when the mechanical system is prevented frommoving), F and u are force and velocity on the mechan-ical side, Zm is the mechanical impedance, and 7̂m andTme represent transduction coefficients that describe theelectromechanical coupling. Although this model is phe-nomenological, certain loss mechanisms based on physicaleffects such as eddy currents have also heen incorpo-rated (1).

Magnetization Models. Magnetization plays a funda-mental role in both the magnetostriction that arises fromthe rotation of magnetic moments (actuator mode) andthe change in magnetic anisotropy that occurs when thematerial strains (sensor mode). From a modeling perspec-tive, the hysteretic phenomena that arise as magnetic mo-ments rotate in response to magnetic fields, stresses, orthermal energy are often the primary magnetization at-tribute that needs to be quantified. Models for magneti-zation hysteresis in ferromagnetic materials range frommicromechanical models to phenomenological characteri-zations. Micromechanical models (28,62) describe the cou-pled magnetoelastic interactions through first-principlesformulations that involve the elasticity, thermodynamics,and the electromagnetic energy states. This can lead tohighly accurate results at the magnetic domain level, butthe large number of parameters required currently pro-hibits implementing micromechanical models at the sys-tem level. The Preisach model has been extensively used tocharacterize the magnetization of ferromagnetic materials,and more recently of magnetostrictive materials as well(63-66). This model approximates the multivalued bys-teretic map by employing a parallel collection of operators.This method has the advantage of intrinsic generality, buttypically it requires identifying a large number of nonphys-ical parameters, and it does not employ or provide insightsregarding the dynamics of the system. One advantage ofthis method is that the Preisach operator can be invertedto facilitate linear control design. Domain rotation mod-els include the classical anisotropic formulation of Stonerand Wohlfarth (18) and later extensions to include cubicEuiisotropies (67) and compressive loading effects (19). Amore complete generalization includes anisotropy, magne-toelastic, and field energies in all three spatial directions(20). Although model results agree well with measureddata, identifying the fractional occupancies that define theparticipation of different easy axes in the total magneti-zation is rather complex. The domain wall theory of Jilesand Atherton has provided accurate results in ferromag-netic (68), magnetostrictive (30,69), and ferroelectric (70-72) materials. This model is constructed from a thermody-namic difference between the magnetic energy availableto magnetize a material and the energy lost as domainwalls attach to and detach from inclusions or pinning sitesin tbe material. This yields a set of differential equationsthat depend on five physical parameters which quantify re-versible, irreversible, and total magnetization changes. Inthe limit when domain wall pinning goes to zero, the Jiles-Atherton model reduces to Langevin's anhysteretic func-tion, although alternative anhysteretic models that employ

the Isin spin relation have been studied (72). Finally, theJiles-Atherton model has heen employed in combinationwith Eq. (8) to map the H-X constitutive relationship (24),and later with dynamical transducer effects to provide aset of reciprocal constitutive relationships among H, M, e,and a (30,69). This modeling approach has proven usefulin inverse compensation designs (73), characterization ofcollocated actuation and sensing in transducers (74), andquantification of the A.E effect in magnetostrictive materi-als (75).

CONCLUDING REMARKS

Magnetostrictive materials are a class of smart materialsthat can convert energy between the magnetic and elasticstates. The phenomenon of magnetostriction is ultimatelydue to the coupling hetween magnetic moment orientationand interatomic spacing, or magnetomechanical coupling.This type of coupling provides a mechanism for bidirec-tional conversion of energy between magnetic and elasticregimes which is attractive for actuator and sensor systemsbecause it does not degrade in time and it provides almostimmediate response. Newer materials such as Terfenol-Dor amorphous metallic ribbons exhibit a unique combi-nation of high forces, strains, energy densities, operatinghandwidths, and coupling coefficients that justify their usein an ever-increasing number of applications ranging frommicropositioners to vibration control systems for heavymachinery. The excellent performance of magnetostrictivematerials is sometimes obscured by the large magnetichysteresis losses and substantial nonlinear effects exhib-ited by these materials when operated at the high regimesin which their attributes become more prominent. In thissense, realizing the full potential of magnetostrictive ma-terials presents rigorous engineering challenges in a waythat other less capable smart materials do not. However,as evidenced by the increasing number of patented deviceshased on magnetostrictive principles, designers continueto overcome these challenges and make advances in de-signing, modeling, and controlling magnetostrictive trans-ducers. Furthermore, clever transducer designs are possi-ble solely due to the rich performance space that arisesfrom the otherwise undesirable nonlinear characteristicsof these materials. As material advances continue, it is ex-pected that magnetostrictive device designers will find newmagnetostrictive solutions for an ever-growing variety oftransducer applications.

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