NARI - ntrs.nasa.gov

35
NARI NJlSA . ' · ·• . NASA AERONAUTICS RESEARCH INSTITUTE Self-Repairing Fatigue Damage in Metallic Structures for Aerospace Vehicles Using Shape Memory Alloy Self-Healing {SMASH) Technology Investigators: M. Clara Wright, NASA KSC 1 Michele Manuel, University of Florida 2 Terryl Wallace, NASA LaRC 3 Andy Newman, NASA LaRC Gate Brinson, Northwestern University 4 ' . . Team members: Hunter Henderson 2 , Mike Kessler 2 , Alanna Eilenberg 2 Oscar Figueroa 111 2 3 , Jeff Sampson 1 , Thad Johnson 1 , Fernando Reyes-Tirado 1 , Ping ping Zhu 4 NASA Aeronautics Research Mission Directorate (ARMD) 2015 LEARN/Seedling Technical Seminar March 18 & 19, 2015

Transcript of NARI - ntrs.nasa.gov

Page 1: NARI - ntrs.nasa.gov

NARI NJlSA . ' ··•.

NASA AERONAUTICS RESEARCH INSTITUTE

Self-Repairing Fatigue Damage in Metallic Structures for Aerospace Vehicles Using

Shape Memory Alloy Self-Healing {SMASH) Technology

Investigators: M. Clara Wright, NASA KSC1

Michele Manuel, University of Florida2

Terryl Wallace, NASA LaRC3

Andy Newman, NASA LaRC Gate Brinson, Northwestern University4

' . .

Team members: Hunter Henderson2 , Mike Kessler2 , Alanna Eilenberg2• Oscar Figueroa 1112•3,

Jeff Sampson1 , Thad Johnson1 , Fernando Reyes-Tirado1 , Ping ping Zhu4

NASA Aeronautics Research Mission Directorate (ARMD)

2015 LEARN/Seedling Technical Seminar

March 18 & 19, 2015

Page 2: NARI - ntrs.nasa.gov

'

March 18 & 19, 2015

Outline

•The innovation: SMASH technology

•Liquid-assisted self-healing approach

•Impact of the innovation

•Results of the Seedling Phases I and II efforts

•Distribution/dissemination

•Next Steps

... .... NASA A!!ronau! ics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar

NJlSA . ' .. ...

' . .

..

2

Page 3: NARI - ntrs.nasa.gov
Page 4: NARI - ntrs.nasa.gov

SMASH Technology • Proof of concept: healing em-long cracks with

retention of mechanical properties 95% recovery of ultimate tensile strength

original

healed

Time-lapse video showing actual healing of two overload cracks on a Sn-Bi dog bone specimen.

NJlSA . ' .. ...

' . .

Healing continues when the specimen is held at temperature and partial matrix liquefaction fills in any remaining gaps in the crack faces.

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 4

Page 5: NARI - ntrs.nasa.gov

Technical Approach

• Liquid-assisted healing of fatigue cracks

• Thermodynamic design of matrix

Binary and Ternary alloy design

Optimization of healing parameters

Optimization or microstructure and mechanical properties

• Complex specimen fabrication

- Multi-layer specimens

• Numerical modeling

At.omtC" P•rC"f'nt. l~tmut.h

-1--· -·;;....,; • • tO .. •

80 Virgin 70

60

l so ~ i 40

~ 30 Post-heal

"' 20

10

0

Bo

0 0.02 004 006

Model validation

Reinforcement architecture

Sttaln

Proof of concept material (top) and mechanical properties of cast AI-Si

material (bottom)

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 5

Page 6: NARI - ntrs.nasa.gov

Impact of Innovation NJlSA . ' .. ...

' . .

Wrought and cast AI alloys used throughout aircraft

Fatigue and fatigue crack growth at high cycles is concern.

Improve damage tolerance and fatigue life of metals at critical structural locations

Integrated self -repairing approach would improve durability and sustainability of the aerospace material to ensure vehicle safety

Mallrill Pnltll~lo1: CorNSian R:G • Fallgot Ctaclt GIOWUI CYS • Comprawve Yield Sbenttb FT • Fracture Tottlul ...

I ; a •

1 SS • Sheer Slrangtb

FAT • i. TS • Ttntllt Sbtll!ll~ ( ~.ut aot criUcal. design re-ulttmtnl

Property Requirements for Jetliner and Military Transport Applications

Upoer Wing Skin Boset.ne. /~t//!J1,/(Y...!,- t/9'Jt NOW Product$ I ;C,!t l/92 n-.. :, lf/!..1, AI LJ UW-P2

Integral Spars/Ribs Bas<!llne 708f>.T7651 7(Y.,().7011).J7651 71*T7751 New PrOdUCIS 2397-T87. /DB!rT74SI CS!IT 11X AI U TP I ,AI U TP·2

Jnttrnal Stfucturt of Fuselage Ba!<~hn9 7056'7011YT040-T74SI 7tSO-T7751

Fuselage Skln1Strlnger$1Fremes Bas<!llne Ale :624-13 Silt~. M; 6013-Tll HOT Sk•n New Product< Al-ll ;>(NiC).nE30 Sic.-. 7~<;. T702

l~-,

Green ::Commercial

Now Produc~ Alolo7:)117·Tfl7 Al-1.1 :>O®-T86. 7011-';.T14~1 C85T·TTX.AJ.tl ~T811S,AJ.tHP·1 AI-U.TP-2

Blue = Under Development

Heinimann eta/, Alcoa, "Advanced Metallic and Hybrid Structural Solutions for Ught-Weight, Long-Uved Aerospace Structures

Aircraft Airworthiness & Sustainment Conference 2012

M arch 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technica l Seminar 6

Page 7: NARI - ntrs.nasa.gov

Results from Phase I NJlSA . ' .. ...

• Self-repair of AI matrix materials

• Fatigue crack repair

Before: Post-Fatigue Testing at KSC ---...

---· ~-

• 90% recovery of UTS after healing After :Post-HealatUF

• Multiple healing cycles achieved

Fatigue crack healed in POC

Adequate A l-Si microstructure for healing treatment Small-scale multi-ply AI-Cu-Si specimen

March 18 & 19, 2015 NASA Aeronautics Research M ission Directorate 2015 LEARN/Seedling Techn ica l Seminar

' . .

7

Page 8: NARI - ntrs.nasa.gov

Phase I Fatigue Testing Results • Fatigue testing of matrix

material after various healing cycles to study liquid-assisted portion of healing.

0 .30

-tn <I> ~ u 0.25 c -

After first t est

NJlSA . ' .. ...

' . .

After second test After second heal ~

:5 0 .20 0') c <I> -~ u 0.15

~ u

A e Before healing .& After 1st healing D After 2"d healing

0.10 ...____----' __ ___._ __ _.__ _ ____.

0 1000 2000 3000 4000

Cycle count, N (x 1 ,000)

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 8

Page 9: NARI - ntrs.nasa.gov

Phase II Results: Fabrication Technique

• Improved upon diffusion bonding technique developed during Phase I by consolidating using

vacuum hot pressing (VHP)

- Larger scales

- Alignment fixtures

- Multi-step processing

Optimized pressures and temperatures 25 mm

NJlSA . ' .. ...

' . .

• Allowed for fabrication of more complex test VHP specimens

. spec1mens

• Ensured adequate SMA reinforcement by X-ray

and computed tomography (CT)

EDM of VHPdogbone CT scan of VHP dog bone

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 9

Page 10: NARI - ntrs.nasa.gov

Phase II Results: Fabrication Technique NJlSA . ' .. ...

I

• VHP samples had a similar microstructure to the cast samples with a decrease in porosity.

• Diffusion bonding interface around wires and between "slices" of matrix material were adequate.

Slight bonding line visible, but no contaminants were identified at the interface.

\

March 18 & 19, 2015

' . .

Page 11: NARI - ntrs.nasa.gov

Phase II Results: Healing overload cracks

NJlSA . ' .. ...

' . .

Comparison of cast and healed mechanical properties

• Increase in ductility 100

when compared to cast - 80 VHP, pre-heal

samples from Phase I ~ 60 ~ -Resulted in necking of (/\

(/\

40 ~

test specimen I.. .w

"' Healing treatment

20

showed filling of crack 0

a 0 _2% = 39.2 Mpa EvHP =9.1 %

0 2 4 6 8 10

Cast overload VHP overload sample pre-healing sample pre- and

post -healing

Strain(%)

VHP overload sample pre- and post-healing Post-Healed Crack

1 II 'Ill 'lq ' 1'' ' 1' ''1''' 1 '~ '1'''1'''1'''1'" 1'''1'''1'''1" 1' 111''" ''I'' '1'''1 o 1 2 3 4 s·

March 18 & 19, 2015 NASA Aeronautics Research M ission Directorate 2015 LEARN/Seedling Techn ica l Seminar 11

Page 12: NARI - ntrs.nasa.gov

Phase II Resu Its: Driver for treatment optimization

• CT stills showing diffusion front of wire within healed overload composite

VHP overload sample post-healing (SMA reinforcements) VHP overload sample post-healing

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar

NJlSA . ' .. ...

' . .

12

Page 13: NARI - ntrs.nasa.gov

Phase II Results: Driver for treatment optimization

• Non-destructive CT vs. destructive metallography showing diffusion of SMA constituents into matrix.

NJlSA . ' .. ...

' . .

CT of VHP overload sample post-healing Metallographic specimen of VHP overload sample post-healing

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 13

Page 14: NARI - ntrs.nasa.gov

Phase II Resu Its: Driver for treatment optimization

NJlSA . ' .. .. _

• Sacrificial damage of SMA with original healing treatment

X-ray dot map of VHP sample after 24-hr healing treatment. Red = Ni, Green = Si

-----~~--..

X-ray dot maps of VHP sample after 24-hr healing treatment. AI, Si, Ti, and Ni shown

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar

' . .

14

Page 15: NARI - ntrs.nasa.gov

Phase II Results: Healing Treatment Optimization

• Optimization of:

Microstructure

Mechanical properties

Healing treatment

NJlSA . ' .. ...

' . .

VHP specimens after healing treatment for various time periods.

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 15

Page 16: NARI - ntrs.nasa.gov

Phase II Results: Healing Treatment Optimization

• Optimization of:

Microstructure

Mechanical properties

Healing treatment

NJlSA . ' .. ...

' . .

VHP specimens after healing treatment for various time periods.

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 16

Page 17: NARI - ntrs.nasa.gov

Phase II Results: Healing Treatment 0pti m ization

• Optimization of:

Microstructure

Mechanical properties

Healing treatment

NJlSA . ' .. ...

' . .

VHP specimens after healing treatment for various time periods.

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 17

Page 18: NARI - ntrs.nasa.gov

Phase II Results: Healing Treatment Optimization

• Optimization of:

Microstructure

Mechanical properties

Healing treatment

NJlSA . ' .. ...

' . .

VHP specimens after healing treatment for various time periods.

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 18

Page 19: NARI - ntrs.nasa.gov

Phase II Results: Healing Treatment Optimization

• Optimization of:

Microstructure

Mechanical properties

NJlSA . ' .. ...

' . .

VHP specimens after healing treatment for various time periods.

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 19

Page 20: NARI - ntrs.nasa.gov

Phase II Results: Healing Treatment Optimization

• Optimization of:

Microstructure

Mechanical properties

Healing treatment

NJlSA . ' .. ...

' . .

VHP specimens after healing treatment for various time periods.

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 20

Page 21: NARI - ntrs.nasa.gov

Phase II Results: Healing Treatment Optimization

• Optimization of: Microstructure

Mechanical properties

Healing treatment

• Grain growth and diffusion vs. mechanical properties

1110 _ ____ ___ _l 90·

~ < RO .. .... Percent \VtN Area Rcnliining

e ~ 70 · ... AlSi (MPoJ uncorrected ~ i ~ (,() c.." a.~~o-

-s ~ olO • 5' bl 30 ~ ..:! 20-.l!

10 -

o------------~--~-----------10 100 1000

lluhna 'lome Inion)

NJlSA . ' ". ·•.

' . .

Optimization of healing treatment VHP specimens after healing treatment for various time periods.

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 21

Page 22: NARI - ntrs.nasa.gov

Phase II Results: Fatigue Crack Growth NJlSA . ' .. ...

' . .

• Edgewise single edge notch tension ESE(T) specimens tested by compliance control to grow and heal a small fatigue crack. - Surface strain measurements via visual image correlation (VIC-3D)

• FCG specimens were pre-cracked, tested, healed, and re-tested. High-temperature speckle pattern was used to continue strain

measurements after healing treatment.

ESE(T) specimen with speckle paint and relative location of SMA reinforcements.

ESE(T) specimen during FCG test with VIC data superimposed.

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 22

Page 23: NARI - ntrs.nasa.gov

Phase II Results: Fatigue Crack Growth N~SA . ' .. ' . .

• Pre-healing treatment CT

CT movies of ESE(T) FCG specimen pre-healing treatment.

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 23

Page 24: NARI - ntrs.nasa.gov

Phase II Results: Fatigue Crack Growth NJlSA . ' .. ...

• Strain fields during first fatigue test, after healing, and at the end of the second fatigue test.

VIC strain field data of ESE(T) FCG specimen pre- and post-healing treatment.

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar

. ...

"

10

' . .

24

Page 25: NARI - ntrs.nasa.gov

Phase II Results: Modeling NJlSA . ' .. ...

• Modeled composite using various loading scenarios, SMA compositions, wire placement, continuous vs. discontinuous wire lengths, and wire pre-strain .

Evaluated plasticity induced on the matrix and wires from loading, unloading, and heating to healing temperatures.

Evaluated ability of SMA wires to force crack closure in the SMASH materials system.

Three-Point Bend Tensile Rectangular Plate

Roller constrain

Pinned Pinned

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar

' . .

25

Page 26: NARI - ntrs.nasa.gov

Phase II Results: Validation of Model NJlSA . ' .. ...

' . .

• Empirical and model of metal matrix composite 3-point bend tests were in agreement

True test data, including material properties at different temperature regimes, was used in the model.

Simulation of crack opening displacement {COD} after unloading is in good agreement with the test measurements.

Final COD after loading: • Model: 0.17 mm

• Experimental : 0.15 mm

Crack length = 7.6 mm

Crack Opening Displacement (model)

0.3 -r-----------------,

0 5

0.25 mm

10 15 Time (s)

20

E = 65 GPa for Sn-Bi matrix

25 30

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 26

Page 27: NARI - ntrs.nasa.gov

Phase II Results: FEA NJlSA . ' .. ...

' . .

• FEA showing stress evolution (von-Mises, MPa) upon loading, unloading, and heating.

Step 1: Load Step 2: Unload Step 3: Heat

SMA

Matrix

March 18 & 19, 2015 NASA Aeronautics Research M ission Directorate 2015 LEARN/Seedling Technical Seminar

S. Mice:c

1,_,~~~-'

•1 7 00hC2 -.1 A92C+C2 .. 1074s.C2 .. t .l SOC+Cl .. 3!59DuC1 1-DOOOhCO

Mal(: - 4 275t.02 Eliir1' : PA~T~9· I .5 NOQI ! :IC!

27

Page 28: NARI - ntrs.nasa.gov

Applying FEA to Fabrication of Complex Specimens

• 3-D model

Matrix SMA

NJlSA . ' .. ...

' . .

10· I ._ _ _,._ _ _____c

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 28

Page 29: NARI - ntrs.nasa.gov

Applying FEA to Fabrication of Complex Specimens

• FEA was used to model two multi-ply hot pressed specimens: - -45/0/+45

- -30/0/+30

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar

NJlSA . ' .. ...

' . .

29

Page 30: NARI - ntrs.nasa.gov

c (}.) (}.)

s +-' (}.)

...0 (}.) () c m +-' (/) ·-0

Phase II Results: Using FEA for

Extending the Realm of possibilities • The best wire placement in relation to the crack is

perpendicular (0° in figures below)

• Pre-stra ining re inforcements aids in crack closure

0.6

0.5

...--....

E 0.4

E ...__....

N 0. ~

o6 .._-(/) O..J (}.) -o 0 c 0.1

0

l

4

I

Unload Heat

n . ..;

- l ">rk;; 0.1

- ..J' Ct';-i O.l

l\ 1

Load Unload Heat

NJlSA . ' ·· ·•.

' . .

-odeg

- 1sdeg

30deg

- 4Sdeg

{l ),1 25 30

Time (s) Time (s)

March 18 & 19, 2015 NASA Aeronautics Research M ission Directorate 2015 LEARN/Seedling Technical Seminar 30

Page 31: NARI - ntrs.nasa.gov

Phase II Results: Using FEA for

Extending the Realm of possibilities • Short vs. Long fibers

NJlSA . ' .. ...

' . .

Continuous vs. discontinuous wire reinforcements were modeled.

The best case for crack closure is continuous reinforcements near the crack tip. Case 1 -discontinuous wires parallel

j ....,::.-- ------

- ease1 0.06 mm - easel - easel Case 2: discontinuous wires, offset by 12 mm

0 10 15 25 30

Case 3: discontinuous wires, offset by 20 mm

~' node1 node2 20mm

March 18 & 19, 2015 NASA Aeronautics Research M ission Directorate 2015 LEARN/Seedling Technical Seminar 31

Page 32: NARI - ntrs.nasa.gov

Phase II Results: Matrix Alloy Design

• AI-Cu and AI-Cu-X systems

• Liquid-assisted step in healing:

- Eliminates work hardening and grain refinement

- Leaves precipitation hardening and solid solution strengthening

• Candidates:

- AI-Cu-Mg alloys that can precipitate the high-strength S-phase and its metastable precursors

• Heat treatment:

Cast, solution treat, quench, and age to peak strength.

Healing treatment performed on diffusion couples

Perform heat treatment again.

M arch 18 & 19, 2015 NASA Aeronaut ics Research M ission Directorate 2015 LEARN/Seedling Technical Seminar 32

Page 33: NARI - ntrs.nasa.gov

Distribution/Dissemination NJlSA . ' .. . ..

• Patents: - A provisional patent application titled "Self-Repairing Metal Alloy Matrix Composites, Methods of

Manufacture and Use Thereof" was fi led in June 2014 with the Patent and Trademark Office.

• NASA Technical Memoranda

' . .

Fatigue Resistance of Liquid-Assisted Self-Repairing Aluminum Alloys Reinforced with Shape Memory Alloys

Assessment of Fatigue Crack Damage and Mitigation in Self-Repairing Metallic Materials

• Invited Talks: - TMS 2015 Annual Meeting and Exhibition, March 2015 in Orlando, FL "Investigating the Fatigue Behavior of

Aluminum-Based Shape Memory Alloy Self-Healing (SMASH) Technology".

• Other Conference Talks: Aerospace Materials (AeroMat) Conference in June 2014 in Orlando, FL. " Amending Fatigue Damage Using Shape Memory Alloy Self-Healing {SMASH) Technology" .

International Conference of Self Healing Materials, Ghent, June 2013, "Design Methodology for Liquid­Assisted Self-Healing Metals".

• Media, Articles and Public Relations: Central Florida Fox 35 News, January 2014

NASA web article I september 2 013 I http://www.nasa .gov /content/smash-alloys-being-designed-to-improve-aerospace-safety-margins/

NASA video highlight: http://www.youtube.com/watch?v=VBgGpkesHQo

Professor Michele Manuel was deemed as one of three top researchers with ground breaking research at the University of Florida in part because of the SMASH research, UF Alumni Magazine "Shaping the Future", Spring 2014.

March 18 & 19, 2015 NASA Aeronautics Research M ission Directorate 2015 LEARN/Seedling Techn ical Seminar 33

Page 34: NARI - ntrs.nasa.gov

Next Steps NJlSA . ' .. ...

• Currently planning on 7 peer-reviewed journal articles - 1 high-level (in work), 2 modeling papers, 2 materials journals, 2

mechanics of materials.

• No-cost extensions granted to universities to complete experimental and modeling work for next 3 to 9 months.

- Includes testing of multi-ply specimens and precipitation hardened matrix alloys.

• Interest from the Space Technology Mission Directorate to continue work on embedded crack detection and surface or non-contact heating.

• Potential collaboration with JPL to further enhance matrix design.

• Continue to market technology to other NASA Principal Investigators

March 18 & 19, 2015 NASA Aeronautics Research M ission Directorate 2015 LEARN/Seedling Technical Seminar

' . .

34

Page 35: NARI - ntrs.nasa.gov

Summary/Conclusions

• Proved healing of fatigue and overload cracks in proof-of­concept and aluminum matrix composites

• Performed fatigue crack growth tests before and after healing

• Experimentally optimized the processing parameters, healing treatment, matrix heat treatment

• Finite element model optimized the SMA reinforcement geometry, length, and pre-strain conditions

• Validated computer model using experimental data.

THANK YOU ARMD and NARI!

March 18 & 19, 2015 NASA Aeronautics Research Mission Directorate 2015 LEARN/Seedling Technical Seminar 35