High resolution, wide field-of-view, infrared (IR) imagers find use in defense and civilian applications. The most demanding of them desire uniform sensitivity across an image’s field of view, while maintaining a small and light-weight optical design. These attributes can be achieved by curving of the focal plane array to reduce the need for field curvature correction. Using experimental and numerical methods, we investigated the spherical curving of hybridized arrays to demonstrate mechanical feasibility and opto-electronic performance. Each hybridized array comprised a 4k x 4k, 10 μm pixel pitch, midwave IR (MWIR) detector hybridized to a 67 mm diagonal fanout chip. We curve an array to 139.2 mm radius of curvature, resulting in a pixel area coverage of 0.086 sr. Measurements across the curved array revealed minimal variation in bandgap (<0.1 μm) and no appreciable difference in dark current.
KEYWORDS: Foam, Finite element methods, Neodymium, Composites, Electroluminescence, Performance modeling, Chemical elements, Surface conduction electron emitter displays, Solids, Vibration control
Structural assemblies incorporating negative stiffness elements have been shown to provide both tunable damping properties and simultaneous high stiffness and damping over prescribed displacement regions. In this paper we explore the design space for negative stiffness based assemblies using analytical modeling combined with finite element analysis. A simplified spring model demonstrates the effects of element stiffness, geometry, and preloads on the damping and stiffness performance. Simplified analytical models were validated for realistic structural implementations through finite element analysis. A series of complementary experiments was conducted to compare with modeling and determine the effects of each element on the system response. The measured damping performance follows the theoretical predictions obtained by analytical modeling. We applied these concepts to a novel sandwich core structure that exhibited combined stiffness and damping properties 8 times greater than existing foam core technologies.
Over 60% of energy that is generated is lost as waste heat with close to 90% of this waste heat being classified as
low grade being at temperatures less than 200°C. Many technologies such as thermoelectrics have been proposed as
means for harvesting this lost thermal energy. Among them, that of SMA (shape memory alloy) heat engines appears
to be a strong candidate for converting this low grade thermal output to useful mechanical work. Unfortunately,
though proposed initially in the late 60's and the subject of significant development work in the 70's, significant
technical roadblocks have existed preventing this technology from moving from a scientific curiosity to a practical
reality. This paper/presentation provides an overview of the work performed on SMA heat engines under the US DOE
(Department of Energy) ARPA-E (Advanced Research Projects Agency - Energy) initiative. It begins with a review
of the previous art, covers the identified technical roadblocks to past advancement, presents the solution path taken to
remove these roadblocks, and describes significant breakthroughs during the project. The presentation concludes with
details of the functioning prototypes developed, which, being able to operate in air as well as fluids, dramatically
expand the operational envelop and make significant strides towards the ultimate goal of commercial viability.
Current seals used for vehicle closures/swing panels are essentially flexible, frequently hollow structures whose designs
are constrained by numerous requirements, many of them competing, including door closing effort (both air bind and
seal compression), sound isolation, prevention of water leaks, and accommodation of variations in vehicle build. This
paper documents the first portion of a collaborative research study/exploration of the feasibility of and approaches for
using active materials with shape and stiffness changing attributes to produce active seal technologies, seals with
improved performance. An important design advantage of an active material approach compared to previous active seal
technologies is the distribution of active material regions throughout the seal length, which would enable continued
active function even with localized failure. Included as a major focus of this study was the assessment of polymeric
active materials because of their potential ease of integration into the current seal manufacturing process. In Part 1 of
this study, which is documented in this paper, potential materials were evaluated in terms of their cost, activation
mechanisms, and mechanical and actuation properties. Based on these properties, simple designs were proposed and
utilized to help determine which materials are best suited for active seals. Shape memory alloys (SMA) and
electroactive polymers (EAP) were judged to be the most promising.
Airflow over/under/around a vehicle can affect many important aspects of vehicle performance including vehicle drag
(and through this vehicle fuel economy), vehicle lift and downforce (and through these vehicle stability and handling),
and cooling/heat exchange for the vehicle powertrain and air conditioning systems. Known devices in current use to
control airflow over/under/around the vehicle are all of fixed geometry, location, orientation, and stiffness. Such devices
can thus not be relocated, reoriented, reshaped, etc. as driving conditions change and thus airflow over/under/around the
vehicle body cannot be adjusted to better suit the changed driving condition. Additionally, under-vehicle airflow control
devices, such as air dams, also reduce ground clearance and thus present a constant challenge to designers to provide the
needed control of airflow while maintaining sufficient ground clearance to avoid damage. The research project whose
second phase is described herein had its genesis in brainstorming on ways in which the field activated shape and stiffness
changing attributes of several classes of active materials could be utilized to produce on-demand deploying/stowing of an
air dam. During this second phase, bench top working models were developed, constructed, and successfully exercised
this demonstrating the feasibility of an SMA actuator based approach to reversibly deploying an air dam through
bending of its flexible structure. Beyond feasibility, the bench top working models demonstrated an active materials
based approach which would add little weight to the existing stationary system, and could potentially perform well in the
harsh under vehicle environment due to a lack of bearings and pivots. This demonstration showed that actuation speed,
force, and cyclic stability all could meet the application requirements.
Morphing or reconfigurable structures potentially allow for previously unattainable vehicle performance by
permitting several optimized structures to be achieved using a single platform. The key to enabling this technology in
applications such as aircraft wings, nozzles, and control surfaces, are new engineered materials which can achieve the
necessary deformations but limit losses in parasitic actuation mass and structural efficiency (stiffness/weight). These
materials should exhibit precise control of deformation properties and provide high stiffness when exercised through
large deformations. In this work, we build upon previous efforts in segmented reinforcement variable stiffness
composites employing shape memory polymers to create prototype hybrid composite materials that combine the benefits
of cellular materials with those of discontinuous reinforcement composites. These composites help overcome two key
challenges for shearing wing skins: the resistance to out of plane buckling from actuation induced shear deformation,
and resistance to membrane deflections resulting from distributed aerodynamic pressure loading. We designed,
fabricated, and tested composite materials intended for shear deformation and address out of plane deflections in variable
area wing skins. Our designs are based on the kinematic engineering of reinforcement platelets such that desired
microstructural kinematics is achieved through prescribed boundary conditions. We achieve this kinematic control by
etching sheets of metallic reinforcement into regular patterns of platelets and connecting ligaments. This kinematic
engineering allows optimization of materials properties for a known deformation pathway. We use mechanical analysis
and full field photogrammetry to relate local scale kinematics and strains to global deformations for both axial tension
loading and shear loading with a pinned-diamond type fixture. The Poisson ratio of the kinematically engineered
composite is ~3x higher than prototypical orthotropic variable stiffness composites. This design allows us to create
composite materials that have high stiffness in the cold state below SMP Tg (4-14GPa) and yet achieve large composite
shear strains (5-20%) in the hot state (above SMP Tg).
Reconfigurable and morphing structures may provide significant improvement in overall platform performance through
optimization over broad operating conditions. The realization of this concept requires structures, which can
accommodate the large deformations necessary with modest weight and strength penalties. Other studies suggest
morphing structures need new materials to realize the benefits that morphing may provide. To help meet this need, we
have developed novel composite materials based on specially designed segmented reinforcement and shape memory
polymer matrices that provide unique combinations of deformation and stiffness properties. To tailor and optimize the
design and fabrication of these materials for particular structural applications, one must understand the envelope of
morphing material properties as a function of microstructural architecture and constituent properties. Here we extend our
previous simulations of these materials by using 3D models to predict stiffness and deformation properties in variable
stiffness segmented composite materials. To understand the effect of various geometry tradeoffs and constituent
properties on the elastic stiffness in both the high and low stiffness states, we have performed a trade study using a
commercial FEA analysis package. The modulus tensor is constructed and deformation properties are computed from
representative volume elements (RVE) in which all (6) basic loading conditions are applied. Our test matrix consisted of
four composite RVE geometries modeled using combinations of 5 SMP and 3 reinforcement elastic moduli. Effective
composite stiffness and deformation results confirm earlier evidence of the essential performance tradeoffs of reduced
stiffness for increasing reversible strain accommodation with especially heavy dependencies on matrix modulus and
microstructural architecture. Furthermore, our results show these laminar materials are generally orthotropic and indicate
that previous calculations of matrix gap and interlaminar strains based on kinematic approximations are accurate to
within 10-20% for many material systems. We compare these models with experimental results for a narrow geometry
and material set to show the accuracy of the models as compared to physical materials. Our simulations indicate that
improved shape memory polymer materials could enable a composite material that can accommodate ~30% strain with a
cold state stiffness of ~30GPa. This would improve the current state of the art 5-10x and significantly reduce the weight
and stiffness costs of using a morphing component.
Morphing structures have the potential to significantly improve vehicle performance over existing fixed component
designs. In this paper, we examine new composite material design approaches to provide combined high stiffness and
large reversible deformation. These composites employ shape memory polymers (SMP) matrices combined with
segmented metallic reinforcement to create materials with variable stiffness properties and reversible accommodation of
relatively large strains. By adjusting the temperature of the sample, the storage modulus can be varied up to 200x. We
demonstrate the segmented composite concept in prototype materials made using thermoplastic polyurethane SMP
reinforced with interlocking segmented steel platelets. Measured storage moduli varied from 5-12 GPa, below SMP Tg,
and 0.1-0.5 GPa above SMP Tg. The samples demonstrated more than 95% recovery from induced axial strains of 5% at
80°C. Viscoelastic effects are dominant in this regime and we investigate the rate dependence of strain recovery.
Structures that can physically adapt to fulfill many roles can enable a new generation of high-performance military systems. The key to achieving substantial benefit from shape-changing operations is large changes in structural geometry and stiffness. In this study, we demonstrate variable stiffness cellular materials capable of large global changes in area through local buckling modes. Furthermore, stiffness properties and Poisson ratios may be tailored to provide desirable structural reconfiguration properties such as negative Poisson ratio and highly anisotropic stiffness. However, stiffness properties of cellular materials are two to three orders of magnitude below their constitutive materials properties. Their elastic properties can vary considerably as a function of the applied strain level due to the redistribution of structural material within the cells. Another complication is the difficulty in controlling the local buckling mode due to sensitivity to boundary conditions and loading conditions.
Reconfigurable and morphing structures can potentially provide a range of new functionalities including system optimization over broad operational conditions and multi-mission capability. Previous efforts in morphing surfaces have generally focused on small deformation of high stiffness structural materials (e.g. aluminum, CFRP) or large deformation of low stiffness non-structural materials (e.g. elastomers). This paper introduces a new approach to achieving large strains in materials with high elastic moduli (5 to 30+ GPa). The work centers on creating variable stiffness composite materials which exhibit a controllable change in elastic modulus (bending or axial) and large reversible strains (5-15%). Several prototype materials were prepared using a commercial shape memory polymer, and measurements on these materials indicate a controllable change in stiffness as a function of temperature along with large reversible strain accommodation. We have fabricated and tested several design variations of laminar morphing materials which exhibit structural stiffness values of 8-12 GPa, changes in modulus of 15-77x, and large reversible bending strain and recovery of 2% area change in specific sample types. Results indicate that significant controllable changes in stiffness are possible.
Reversible electrochemical compound formation has considerable potential to form the basis of a high-strain high-force multifunctional actuator technology. We present preliminary experimental demonstrations of the reversible work capability of solid-state electroplating. Our experimental test case is the volume expansion incurred during the reversible electrochemical formation of thin-film Li metal from a ceramic lithium ion storage medium, LiCoO2 as part of the standard operation of a state-of-the-art Li-ion battery. Reversible work is accomplished through the plating or stripping of the pure Li film against an external load. With the active portion of the structure as a basis, we observe ~10% strain against loads up to 2 MPa, with the load being limited by battery failure. No change in actuation characteristics is observed up to failure.
Graphite intercalation compounds are a class of materials systems formed as ions diffuse into a host graphite structure. The volume expansion associated with this process has been shown to be capable of performing work up to 3.8 MJ/m3. To evaluate GICs for solid state actuation, this study explores some factors affecting the rate at which the volume expansion occurs. Given that diffusion length has an exponential effect on rate, we tested a graphite paper comprised of 7-micron diameter PAN fibers. We found that the paper had ultimate strain and loading properties comparable to HOPG. The paper was cycled under various loads and temperatures to examine the strain rate and repeatability of the material. Testing showed a strong correlation between rate and temperature, while pressure had relatively little effect.
The implementation of smaller, lighter, and more agile military systems requires new actuation technologies that offer high power density in compact form factors. The Compact Hybrid Actuator Program (CHAP) is pursuing active material based, rectifying actuators to create new actuation solutions for these demanding applications. Our actuator approach is based on thin film NiTi membranes operating in parallel (high intrinsic power density, >125 kW/kg) combined with liquid rectification, MEMS passive check valves, and commercially available power electronics. Previous results demonstrated 8 micron thick membrane actuation with 150 Hz forced convection response and force output of 100N. This paper focuses on two developments critical in scaling up previous single membrane results to power levels sufficient for military applications. This first is the development of SOI MEMS fabricated microvalve arrays which exhibit high flow rate at high frequencies. The second focus area is the design, fabrication, and assembly of a form factor compact actuator. The initial prototype demonstration of this concept shows great promise for thin film NiTi based actuation both in military technologies and in other areas which demand extremely compact actuation such as embedded fluid delivery for biomedical applications.
Recently, there have been significant advances in using magnetostrictive particles in a polymer matrix; finding uses in many applications, both as an active transducer and a passive dumper. Termed magnetostrictive particulate composites (MPC), the material provides capabilities identical or superior to the monolithic material. Fortis Technologies has been pursuing improvements in the applications and fabrication of this innovative material. Specifically, this MPC technology provides a passive, broadband, large temperature range, high stiffness, damping material to be used where current technologies fall short. A novel manufacturing technique based on magnetic fields has been developed to distribute magnetostrictive particulates in a polymer resin and apply it in thin-layer on surfaces for vibration damping in environments typical of turbomachinery fan blades. These magnetostrictive particulates provide damping through domain wall switching, a non-conservative action which provides a high loss factor, and, in turn, significant vibration mitigation. The magnetostrictive damping composites can be easily fabricated into thin films, provide stiffness and strength while also incorporating damping capabilities which exceed in performance and temperature range viscoelastic materials, the current state of the art for applied blade damping. Analytical studies, a finite element analysis and experimental study of the new material in a typical turbomachinery blade loading condition has been conducted and has demonstrated the benefits of this technology.
Recently, there have been significant advances in using magnetostrictive particles in a polymer matrix; finding uses in many applications, both as an active transducer and a passive damper. Termed magnetostrictive particulate composites (MPC), the material provides capabilities identical or superior to the monolithic material. Fortis Technologies has been pursuing improvements in the application and fabrication of this innovative material. The MPC technology provides a passive, broadband, large temperature range, high stiffness, dampling material to be used where current technologies fall short. Damping applications of this technology include sporting goods, power/hand tools, space launch and satellite design, noise abatement and vibration isolation. Energy absorption of the composites has been measured and is approaching that of the monolithic material. The material can also be actively controlled by a magnetic field, producing a transducer that can be used for sonar applications. The advantage of this technology over those currently in use is the large power density at relatively low frequencies and the ease of fabrication, allowing less expensive and more effective conformal arrays. Effective strain output and piezomagnetic coefficients have been measured, as have its dynamic properties. The results show significant improvement of the strain output and piezomagnetic coefficients, approaching the monolithic material.
Terfenol-D particulate composites have been fabricated with and without a preferred crystal orientation of the particles. A 25% volume fraction polymer matrix composite was fabricated in a magnetic field using geometric anisotropy to orient needle shaped particles with long axis [112] orientation along the length of the composite. Results demonstrate that the magnetostriction of a [112] oriented particle composite saturates near 1600 ppm. This is a significant increase when compared to composites without preferential orientation (1200 ppm). The oriented particle composite exhibits the largest reported magnetostriction for a particulate composite material. The magnetization-strain measurements indicate that the strain in the oriented composite is proportional to the (lambda) 112 saturation magnetostriction while the non-oriented composite is proportional to the polycrystalline saturation magnetostriction, (lambda) pc. In addition, the fields necessary for equivalent magnetostriction in the oriented particle composite are reduced when compared to the non-oriented composite, though both require higher fields than commercially available monolithic Terfenol-D.
Energy absorption properties of polymer matrix Terfenol-D particulate composites have been experimentally measured. In this work two volume fractions of Terfenol-D were investigated and both exhibited peak energy absorption of up to 25 percent per cycle. The tests include mechanical loading in both axial and shear combined with applied axial magnetic fields. The results show that the energy absorbed in a cycle of loading is a strong function of stress amplitude. The peak energy absorption for the zero magnetic field case in both axial and shear loading occurs near zero amplitude and decreases with increasing stress amplitude. The maximum energy absorption near zero stress amplitude has been observed previously in monolithic Terfenol-D and is a result of the low magnetic anisotorpy of Terfenol-D. Combined magnetic-mechanical loading demonstrated the influence of magnetic field on energy absorption properties. The energy absorption is decreased as the static magnetic field is increased if the cyclic stress amplitude is held constant. If however, we hold a constant magnetic field and vary the cyclic stress amplitude is held constant. If however, we hold a constant magnetic field and vary the cyclic mechanical loading amplitude, it has been observed that the peak energy absorption curve is shifted to higher stress values. This suggests stress tunable dampers are possible.
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