SMART MATERIALS AND THEIR STRUCTURAL APPLICATIONS

S.GOPALAKRISHNAN
DEPARTMENT OF AEROSPACE ENGINEERING INDIAN INSTITUTE OF SCIENCE, BANGALORE 560 012

Smart Structures Why this name

Definition of a Smart Structure

Smart Materials and Smart Structures

LOCATION OF SMART DEVICES IN AN AIRCRAFT

Figure 15.1.2: A Schematic view of a Smart Bridge

A Schematic view of a Smart Bridge

What constitutes a smart structure?

Mechanical Structure Sensors Actuators Controllers Signal processing and data reduction

Comparison with biological structures

Useful strengths-to-weight ratio Self-repairing systems Adaptive Joining Mechanisms ( mainly muscles and tendons) Processing is distributed with central monitoring systems (brain) Communication Channels throughout the systems (Neurons) Central processor is highly adaptive and self-configures in the light of experience. Energy transfer mechanisms involve chemically burned distribution systems

Ideal Smart Structure

SMART MATERIALS
Also called Functional Materials A material can be considered smart when a input stimulus of a variable changes the output of other variables not given as input OR A material is smart if a specific response is produced to a combination of inputs

Fiber optic sensors - Types

Principle of Operation

Piezoelectric Materials

Principle of Operation

Embedding Inside Composite

ELECTROSTRICTIVE MATERIALS:
Principle materials - Lead Manganese Niobate: Lead Titanate (PMN:PT) Lead Lanthanum Zirconate Titanate (PLZT) Used for actuation purpose only Electric filed induce charges that attract each other to cause compressive force Force generated is independent of the sign of the electric field. =S+ME 2 Low strain levels up to 1% for a field of 1MV/m Low Hysterisis loop and hence low loss material Suitable for frequencies up to 50 kHz. E= 70GPa and very brittle Fast response time

Magnetostrictive Materials
Phenomenon similar to electrostriction. Can be used for both sensing and actuation TERFENOL-D (alloy of TERbium, Iron (FE) and was made at Naval Ordinance Laboratory, and hence the name TERFENOL-D) Terbium is the rarest of the rare earth material and hence very expensive. Large strain levels (2 %) E = 200GPa and lengths of 200mm Narrow hysterisis loop and hence low loss Generates large actuating force (order of Kilo Newtons)

Some Basic Properties of TERFENOL-D

Non-Linear Constitutive Model of Terfenol-D

SHAPE MEMORY ALLOYS

Made by mixing nickel and titanium T<TCr - Martensitic phase - Plastic state - Large strains can be applied with little stress. T>TCr - Austennitic phase - memory phase - retains its original shape. Actuation is caused by transforming the material from Martensite to Austennitic phase. This process causes enormous amount of stress, which can be used for actuation purpose. Slow reaction time Properties depend on the composition, the phase and past history

ELECTRO-RHEOLOGICAL FLUIDS
Viscous properties are modified by applying electric fields. Obtained by mixing silicone oil and corn starch. In neutral state, particles are uniformly distributed. Under electric field, the large di-electric constants re-distributes the particles changing the viscous properties. E-R Fluid are Non-Newtonian fluids. Useful in transferring shear stresses. Can be used for structural damping in vibration studies.

STRUCTURAL HEALTH MONITORING

The study involving the monitoring, detection and arrest of the growth of flaws such as cracks constitute what is universally termed as Structural Health Monitoring (SHM). SHM has 4 levels, which are the following: Level 1: Confirming the presence of damage. Level 2: Determination of the location, size and orientation of the damage. Level 3: Assessing the severity of the damage and Level 4: Controlling the growth of damage.

Introduction to Structural Health Monitoring

CASE STUDIES

Vibration and Noise Control

Control of interior noise level in rotorcraft

Sources Transmission paths Receiving space Vibration transmitted through gearbox struts (10Hz - 6kHz)

Objective Model based study of active control of wave transmission in helicopter gearbox support strut
Reduction of broadband noise level at the strut-fuselage interface Multiple transmission and scattering of structure- born noise in finite strut : Effect of near-field Simulation of integrated strut-actuator mechanics Handling group of actuators and feedback sensors in non-collocated form

Previous Studies Project Reports & Research Papers

(a) Reduction of Helicopter Interior NOise (RHINO), Joint European Project, 1993/1995 (b) EH101 Vibration Control Program, Westland Helicopter Ltd. 1988/1990 (c) Agusta A-109 Cabin Noise Quieting Program, 1976/1978 (d) Active Control of Vibration Transmission: Research at ISVR

Patents
(a) Active Vibration Control System, Staple et. al., 1993 (b) Helicopter Active Noise Control System, Yoerkie et al., 1994

Active Spectral Element Model (ASEM) for Integrated Strut-Actuator Mechanics

aq Actuator s p Sensor

Zs p x Za p Ls p X sp
PID Controller

X ap La p
Sensor Output: Strut segments
( xs p , zs p , n ) = j n []s p {u }e sp
}e e }e {F s p = [ K ]s p {u sp
(Local) (Global)

} = []ts [ K ]e {F s p [ ]s p {U }s s p
p

Actuator Elements

t e } = []ta [ K ]e {F [ ] { U } + [ ] [ K ] aq aq aq aq s p [ ]s {U }s a a q
q q p

Active strut response for longitudinal wave control at fuselage interface

( xs = 1.0m )

( g = 17 )

Active strut response for longitudinal wave control at fuselage interface using actuator group

xs = 1.0m g = 8.5

xs = 0.9m xa = 0.8m

Summary
Efficient and realistic modeling strategy for MIMO configuration in non-collocated form Accurate estimation of the effect of actuator dynamics and near field effects on sensor Identification of optimal sensor-actuator configuration with constant feedback gain using ASEM : A semi-automated iterative scheme A robust analysis strategy for controlling multi-mode axial-flexural coupled broadband waves transmitted through the strut-fuselage interface using group of actuators Identification of critical bands by analyzing the pole-zero interaction between driving point response and control point response Potential candidate for implementation of Optimal Power Flow Algorithm and design of digital controller based on frequency weighted adaptive gain scheduling

Active Vibration Control in Thin walled

Thin walled Composite Beam Experiences Bending-Axial and Bending Torsion Coupling PZT actuators are used here to reduce fundamental and higher order modes Control Design- PI and Eigen Structure Assignment Technique Objective- Increase damping for reduction in Response

(a )

(b )

PI Controller-Experimental

PI Controller-FE Formulation

Multi Modal Control

SHM OF COMPOSITE WING USING MAGNETOSTRICTIVE SENSORS / ACTUATORS

Principle:

The induced magnetic field in the actuator patch, will cause stress in the sensor patch and hence the Open Circuit Voltage (OCV) across the sensor patch. In the presence of the delamination, the stress and hence the OCV vary according to the size of the delamination. Difference between the OCV of the delaminated and un delaminated configuration (Called the Damage Induced Voltage (DIV)) will give the sensing voltage and hence the confirmation of the presence of delamination

Table :2 Sensing Voltage of the laminate with surface bonded single patch and delamination of 2.4 cm (Experiment)

Table:3 Sensing Voltage of the laminate with surface bonded single patch and delamination of 2.4 cm (FEM)

Freque ncey (Hz) 100 200 300 400

Sensing Voltage (mV)

1mA 2mA 3mA 4mA

Freque ncey (Hz) 100 200 300 400

Sensing Voltage (mV)

1mA 2mA 3mA 4mA

74 78 84 89

82 87 92 96

89 94 101 106

98 103 109 112

72 77 82 90

82 86 91 96

87 93 99 104

97 102 108 113

(a (b ) ) Surface bonded patch at 200 Hz Frequency: (a)

Peak OCV for different delamination locations (a)Experiment (b) FEM

OCV History (b) DIV History as function of current amplitude

Table :11 Sensing Voltage of the laminate with embedded two patchs and delamination at 4 cm from the actuator (Experiment)

Table:12 Sensing Voltage of the laminate with embedded two patches and the delamination at 4 cm from actuator (FEM)

Freque ncey (Hz) 100 200 300 400

Sensing Voltage (mV)

1mA 2mA 3mA 4mA

Freque ncey (Hz) 100 200 300 400

Sensing Voltage (mV)

1mA 2mA 3mA 4mA

0.3 0.4 0.5 0.5

0.5 0.6 0.7 0.8

0.7 0.8 0.8 0.9

0.9 1.0 1.1 1.2

0.4 0.4 0.5 0.6

0.5 0.6 0.7 0.8

0.6 0.7 0.7 0.8

0.8 0.9 1.1 1.2

ON Line SHM- Level 1 and 2

Can Replace NDT Techniques for Damage Assessment Requires efficient damage models with very small system sizes Efficient Damage Detection Techniques that go well with the damage models Wave Based Techniques are most ideal to detect small stiffness changes Spectral Finite Element is best suited Damage models for delamination, fiber breaks, degraded zones, corrosions, debonds etc.

Assumptions on Modeling
No contact action between the sublaminates at the plane of delamination The cross-sections are perfectly straight at the interfaces

Comparison with 2-D FEA

Cantilever beam with delamination

2-D FE Modeling of delamination

FE Analysis
2560 CST elements t = 1 sec

Damaged Spectral Element Analysis

Single Element = 48.828 Hz

Sine pulse modulated at 20 kHz

Comparison with

Transverse velocity at the cantilever tip

Deformed FEM mesh (displacement magnification = 10e5 times)

Delamination Identification

Cantilever beam with delamination

Transverse velocity at the tip

Delamination at Ply-drops

Cantilever beam with delamination at the region of ply-drops

Transverse velocity history at the tip

ASSESMENT OF DAMAGE SEVIRITY AND HEALTH MONITORING USING PZT SENSORS/ACTUATORS Level 3
Principal- Damage induces Change in the Voltage across the sensor Damage Voltage Correlated with Fracture Parameters- SIF or SERR Average Voltage changes for different damage configuration can be obtained Measuring the Voltage can thus give the severity of the damage

ACTUATION OF DCB SPECIMEN UNDER MODE-II DYNAMIC LOADING Level 4

Objective: Control /Delay the growth of Crack/delamination Only Open-Loop Control is considered Simple Sinusoidal Dynamic (Voltage) excitation is considered AC Voltage Both in phase and out of phase is considered

Good reduction in SIF when Voltage is in Phase with load Out of phase voltage has a negative effect

Future Outlook
Use of Carbon nanotube based sensors/actuators for structural application Use of RF MEMS based Sensors/Actuators for Health Monitoring applications Development of thin film technology for the development of sensors/actuators Development of nano composites for enhanced structural and damping properties

Thank You