专利汇可以提供METHOD OF FABRICATING AN ADAPTIVE COMPOSITE STRUCTURE USING SHAPE MEMORY ALLOYS专利检索,专利查询,专利分析的服务。并且Systems and processes that integrate thermoplastic and shape memory alloy materials to form an adaptive composite structure capable of changing its shape. For example, the adaptive composite structure may be designed to serve as a multifunctional adaptive wing flight control surface. Other applications for such adaptive composite structures include in variable area fan nozzles, winglets, fairings, elevators, rudders, or other aircraft components having an aerodynamic surface whose shape is preferably controllable. The material systems can be integrated by means of overbraiding (interwoven) with tows of both thermoplastic and shape memory alloy materials or separate layers of each material can be consolidated (e.g., using induction heating) to make a flight control surface that does not require separate actuation.,下面是METHOD OF FABRICATING AN ADAPTIVE COMPOSITE STRUCTURE USING SHAPE MEMORY ALLOYS专利的具体信息内容。
The present disclosure relates generally to adaptive composite structures capable of changing their shape and, more particularly, to control surfaces (e.g., flight control surfaces) having an adaptive composite structure.
Conventional aircraft typically include a variety of movable aerodynamic devices for controlling the pitch, yaw and roll of the aircraft and for altering the lift characteristics of the aircraft. For example, fixed wing aircraft may include ailerons mounted to the trailing edge of the wings for roll control of the aircraft. The wings may also include flaps or slats mounted to the leading edge of the wings and which may be deployed or deflected downwardly from the wings during certain phases of flight in order to maintain airflow over the wing at high angles of attack.
Flaps may be also mounted to the trailing edges of the wings to increase the amount of lift generated by the wings when the aircraft is moving through the air at relatively slow speeds. Trailing edge flaps are typically deflected downwardly during takeoff to increase lift and are then retracted during the cruise portion of a flight. The flaps may again be deflected downwardly during the approach and landing phases of the flight to reduce the landing speed of the aircraft.
Typically a flight control surface comprises structural and system (e.g., actuation) components which are separate and not integrated until at an assembly level, adding weight and cost to an airplane wing trailing edge structure. A flight control surface that does not require separate actuation is desirable.
The subject matter disclosed herein is directed to systems and processes that integrate thermoplastic and shape memory alloy (SMA) materials to form an adaptive composite structure capable of changing its shape. For example, the adaptive composite structure may be designed to serve as a multifunctional adaptive wing flight control surface. Overall, such design is multifunctional in fulfilling structural and flight control systems specifications. Other applications include incorporating such adaptive composite structures in variable area fan nozzles, winglets, fairings, elevators, rudders, or any other aircraft components having an aerodynamic surface whose shape is preferably controllable. The systems and processes disclosed herein can also be applied to other transportation vehicles (e.g., spoilers used on automobiles and race cars) as well as on wind blades. All of these applications use control surfaces that can benefit from adaptive composite structure using shape memory alloys. The material systems can be integrated by means of overbraiding (interwoven) an expandable mandrel with tows of both thermoplastic and SMA materials or wrapping separate layers (woven or continuous) of each material around an expandable mandrel or any combination of one or more overbraided layers and one or more separate layers of material, and then consolidating and forming the layers surrounding the expandable mandrel in an induction heating tool assembly to make an adaptive composite structure that does not require separate actuation. Induction heating with smart susceptors may be used for consolidation and temperature control during the fabrication process.
The adaptive composite structure, when installed on an aircraft, has an outer mold line which changes shape as the adaptive composite structure deforms in response to heating or cooling of SMA material (also referred to herein as "an SMA actuator"). The SMA actuators can be heated in different ways. In accordance with one embodiment, an SMA actuator is heated by supplying electrical power to a heating blanket which lies adjacent to the SMA actuator. In accordance with another embodiment, an SMA actuator is heated by supplying electrical power to the SMA actuator directly. In accordance with a further embodiment, an SMA actuator is heated by a smart susceptor which lies adjacent to the SMA actuator, which smart susceptor in turn is heated due to eddy currents induced in the smart susceptor by an alternating magnetic field produced by induction coils incorporated in the adaptive composite structure.
An aspect of the invention is a method for fabricating a composite structure comprising: placing a pre-form around and in contact with an exterior surface of a heat-expandable mandrel, wherein the pre-form comprises a first layer comprising shape memory alloy and a second layer comprising thermoplastic material without shape memory alloy, the first layer being disposed between the exterior surface of the mandrel and the second layer; placing the mandrel and pre-form between first and second susceptors disposed between first and second tooling dies of an induction heating workcell; energizing one or more induction coils of the induction heating workcell to produce alternating magnetic fields which cause the first and second susceptors to produce heat, which heat in turn melts the thermoplastic material, softens the shape memory alloy, and expands the mandrel; de-energizing the induction coils of the induction heating workcell after the thermoplastic material has been consolidated to a desired degree and a composite structure has been formed; removing the mandrel and composite structure from the induction heating workcell; and separating the mandrel from the composite structure. In accordance with some embodiments, the first layer of the pre-form comprises tows made of thermoplastic material interwoven with tapes or wires made of shape memory alloy.
Other aspects of adaptive composite structures which integrate thermoplastic and SMA materials are disclosed below.
Reference will hereinafter be made to the drawings in which similar elements in different drawings bear the same reference numerals.
The following detailed disclosure describes methods and apparatus for consolidating and molding/forming a pre-form comprising thermoplastic and shape memory alloy materials and wrapped around a soluble expandable mandrel. These materials may take many different forms. The methodologies disclosed below are suitable for fabricating adaptive composite structures, such as adaptive aerodynamic surfaces of an aircraft.
In accordance with the method depicted n
In accordance with further alternative embodiments, one or more layers of TP material and one or more layers of SMA material (each layer being woven or continuous) can be separately wrapped around an expandable mandrel with a relatively outer layer made of TP material surrounding a relatively an inner layer made of SMA material. For example, the pre-form surrounding the expandable mandrel may comprise a woven or continuous layer of SMA material sandwiched between two woven or continuous layers of TP material.
In accordance with other embodiments, any combination of one or more overbraided or woven TP/SMA layers and one or more separate layers of woven or continuous TP material can be combined to form a pre-form around the exterior surface of an expandable mandrel.
Regardless of the particular combination and configuration of the TP and SMA materials used to create the pre-form, the TP material of the pre-form is consolidated and formed in an induction heating tool assembly to make a composite structure. One TP material which is suitable for use in aerodynamic comprises polyetherketoneketone (PEKK) resin and polyester fibers. For flight control applications, preferably the SMA material is not exposed on the exterior surface of the adaptive composite structure, but rather is covered by or embedded in the TP material during consolidation and forming.
After the composite structure has been formed and removed from the induction heating tool assembly, the SMA material in the composite structure can be trained to give the composite structure the ability to change its shape when the SMA material is heated or cooled with specified temperature ranges. The SMA material can be trained to produce a desired memory effect during such heating or cooling. More specifically, the SMA material in the composite structure can be trained to bend (deform) (optionally, to different degrees) during heating and then return to an undeformed state during cooling. It should be appreciated that the SMA material must be trained in accordance with the constrained motion of the composite structure that is desired. The SMA material can be trained for different degrees of motion based on designs of different "trainers" (mechanical mechanisms used to train a shape memory alloy to maintain its memory shape).
The two main types of shape memory alloys are copper-aluminum-nickel, and nickel-titanium (nitinol) alloys but shape memory alloys can also be created by alloying zinc, copper, gold, and iron. In various embodiments, the SMA material may be nitinol, though various other shape memory alloys of copper, zinc, aluminum, nickel, titanium, palladium, and/or other materials can be used as well. The transition temperature of a shape memory alloy is highly sensitive to the composition of the alloy and can be selected by slightly varying the constituent ratios. The choice of SMA material can be made based upon various design considerations such as operating temperature ranges, desired transition temperatures, desired transition times, combinations thereof, and the like.
Shape memory alloys exhibit thermo-mechanical properties that are useful in constructing thermally actuatable devices. Generally, a shape memory alloy is a metallic alloy that has distinctly different phases on opposing sides of a transition temperature. A shape memory alloy reaches a first physical state when it is below its transition temperature and a second physical state when it is above its transition temperature. Some SMA materials can be trained to have a first shape for the cooler first state and a second shape for the warmer second state. A two-way trained shape memory alloy can forcibly assume the second shape when heated above the transition temperature and then gently return, if not otherwise restricted, to the first shape when cooled to below the transition temperature.
As seen on the left-hand side of
In the example depicted in
The methods of fabricating composite structures disclosed herein involve placing the pre-form and heat-expandable mandrel into an inductively heated matched tooling assembly having a pair of mutually opposing smart susceptor tool faces. The pre-form and heat-expandable mandrel are placed between the smart susceptors. The appropriate susceptor chemistry is selected to provide the desired initial leveling temperature at the surface of the tool during heating of the pre-form. The smart susceptors create the sheet metal shell that forms the face of the inductively heated matched tooling. The mandrel expands and the thermoplastic material melts in response to heating by the smart susceptors.
Still referring to
In some cases, it is preferred that the temperature at which a pre-form is consolidated should not exceed a certain temperature. To this end, the upper and lower susceptors 40 and 42 are preferably so-called "smart susceptors". A smart susceptor is constructed of a material, or materials, that generate heat efficiently until reaching a threshold (i.e., Curie point) temperature. As portions of the smart susceptor reach the Curie temperature, the magnetic permeability of those portions falls to unity (i.e., the susceptor becomes paramagnetic) at the Curie temperature. This drop in magnetic permeability has two effects: it limits the generation of heat by those portions at the Curie temperature, and it shifts the magnetic flux to the lower temperature portions, causing those portions below the Curie temperature to more quickly heat up to the Curie temperature. Accordingly, thermal uniformity of the heated pre-form during the forming process can be achieved irrespective of the input power fed to the induction coils by judiciously selecting the material for the susceptor. In accordance with one embodiment, each susceptor is a layer or sheet of magnetically permeable material. Preferred magnetically permeable materials for constructing the susceptors include ferromagnetic materials that have an approximately 10-fold decrease in magnetic permeability when heated to a temperature higher than the Curie temperature. Such a large drop in permeability at the critical temperature promotes temperature control of the susceptor and, as a result, temperature control of the part being manufactured. Ferromagnetic materials include iron, cobalt, nickel, gadolinium and dysprosium, and alloys thereof.
In accordance with one embodiment, the susceptors are formed of ferromagnetic materials including a combination of iron, nickel, chromium and/or cobalt, with the particular material composition chosen to produce a set temperature point to which the susceptor is heated in response to the electromagnetic energy generated by the induction heating coil. In this regard, the susceptor may be constructed such that the Curie point of the susceptor at which there is a transition between the ferromagnetic and paramagnetic phases of the material defines the set temperature point to which the susceptor is inductively heated.
The consolidation/molding apparatus shown in
In a typical implementation of a consolidation and molding process, the mandrel and pre-form are initially positioned between the upper and lower tooling dies of the stacked tooling apparatus. Then the tooling dies are moved toward each other by hydraulic actuators 46 until they reach their respective tool-closed positions. During the consolidation process, oscillating electrical power is supplied to the induction coils by a power supply 48. The supplied electrical power produces an oscillating magnetic flux which rapidly heats the upper and lower susceptors 40 and 42 to their leveling temperature, which in turn heat the pre-form. During this process, the mandrel will expand and the pre-form will be molded by the opposing contoured (or planar) surfaces of the susceptors 40 and 42.
After consolidation and cooling, the hydraulic actuators 46 move the upper and lower tooling dies 36 and 38 apart to allow removal of the consolidated and formed composite structure from the mold. The hydraulic actuators 46 and the power supply 48 (and also the coolant supply, which is not shown in
The computer program may include settable process parameters for controlling the operation of the electrical power supply and hydraulic actuators. For example, the controller 44 may be programmed to control the electrical power supply 48 and the hydraulic actuators 46 as follows: (a) controlling the electrical power supply 48 to apply a varying low-strength magnetic field having a magnetic flux that passes through surfaces of the smart susceptors until the smart susceptors are heated to a leveling temperature; (b) controlling the hydraulic actuators 46 to apply compressive force to the pre-form equal to a consolidation pressure at least during a time period subsequent to the time when the temperature of the smart susceptors reaches the leveling temperature.
The upper and lower tooling dies 36 and 38 may be made of ceramic and reinforced with a plurality of fiberglass rods that extend longitudinally and transversely in a grid through each die. The dies should not be susceptible to inductive heating so that heating is localized in the retort formed by the susceptors rather than distributed in the press as well. A ceramic that has a low coefficient of thermal expansion, good thermal shock resistance, and relatively high compression strength is preferred, such as a castable fused silica ceramic. Portions of an induction coil are embedded in the dies. In a typical induction heating workcell, respective cavities in the upper and lower tooling dies hold respective tool inserts 36 and 38
The upper and lower tooling dies 36 and 38 may be made of ceramic and reinforced with a plurality of fiberglass rods that extend longitudinally and transversely in a grid through each die. The dies should not be susceptible to inductive heating so that heating is localized in the retort formed by the susceptors rather than distributed in the press as well. A ceramic that has a low coefficient of thermal expansion, good thermal shock resistance, and relatively high compression strength is preferred, such as a castable fused silica ceramic. Portions of an induction coil (not shown in
The retort with installed pre-form and mandrel is heated in accordance with a specified heating profile in order to consolidate the thermoplastic material and form an airfoil-shaped composite structure. For example, the melting point of the TP materials used herein is in a range of about 575 to 650°F, while the melting point of SMA materials is in a range of about 1,000 to 1,200°F, in which case the consolidation temperature may be in the range of 700 to 710°F. Although an inductively heated matched tooling assembly has been disclosed, other suitable heating apparatus can be utilized (e.g., a convection oven). Pressure can be applied internally using the expandable material of the airfoil-shaped mandrel 26. Heat and pressure are applied in a manner intended to cause consolidation of the TP material and deformation of the SMA material.
As previously discussed with reference to the method shown in
Two-way training typically entails thermo-mechanical cycles wherein the SMA object is forced into the desired martensitic and austenitic shapes at respective low and high temperatures.
The composite structures disclosed herein may utilize pairs of mutually antagonistic one-way SMA actuators. In these embodiments, the SMA material is heated to transition from its martensitic shape (i.e., its shape when its crystalline state is martensite) to its austenitic shape (i.e., its shape when its crystalline state is austenite), thereby generating actuation forces for changing the shape of the composite structure. Each one-way SMA actuator changes from its martensitic shape to its austenitic shape when heated sufficiently, stops changing shape when its heating element is de-energized, but then returns to its original shape when the other one-way SMA actuator changes from its martensitic shape to its austenitic shape (although the unheated actuator provides a resistance force that opposes the actuation force produced by the heated actuator).
In accordance with alternative embodiments, two-way SMA actuators can be used instead of paired one-way actuators. To enable two-way reversible actuation, the active portion of each SMA actuator can be fabricated from a two-way shape memory alloy adapted to transition, without an externally applied load, between a first trained shape and a second trained shape when the two-way shape memory alloy is thermally cycled between a first temperature and a second temperature to switch the two-way shape memory alloy from a first state to a second state
When supplied with electrical power, the heating blankets 32 and 34 heat up the active potions of the SMA material, which active portions have been trained to deform during heating from a respective first shape to a respective second shape. The heating blankets 32 and 34 are lightweight when compared to some previously used actuators. The resulting deformation of the heated trained SMA material changes the configuration of the flight control surface.
In accordance with one implementation, the heating blankets 32 and 34 may comprise foil heaters attached to respective interior surfaces of the upper and lower skins 28a and 28b. Each foil heater comprises conductive foil that that has been etched to form a serpentine pattern. During manufacturing, the foil is mounted to a backing and then etched into the desired pattern. The etched foil is then laid up in a dielectric matrix (e.g. silicone), connections (e.g., conductive foil tabs or wires) are led out of the matrix, and the matrix is then consolidated (removing the backing if necessary). Each foil heater is thermally coupled to respective active portions of the SMA material and comprises a serpentine electrical conductor which is connected to the electrical power source 30 by means of a pair of electrical conductors 6 and 8. As electrical current flows through the serpentine electrical conductors of the foil heaters, the active portions of the SMA material will change state in response to sufficient heating.
In an exemplary embodiment, the first state of the two-way shape memory alloy is an austenitic state and the second state is a martensitic state. When thermally activated or heated, the two-way shape memory alloy begins to enter the austenitic state at its austenite start temperature (temperature at which the transformation from martensite to austenite begins on heating). During this martensite-to-austenite transformation, the two-way SMA actuator deforms toward the first trained or austenitic shape. With continued heating, the two-way shape memory alloy eventually completes the martensite-to-austenite transformation at its austenite finish temperature (temperature at which the transformation from martensite to austenite finishes on heating). It should be understood that the austenite start and finish temperatures and rate of the martensite-to-austenite transformation can vary depending on the particular application and its thermal environment, the composition of the shape memory alloy materials being used, and/or the amount and rate of thermal energy applied to the two-way SMA actuator.
Upon cooling, the two-way shape memory alloy begins to enter a martensitic state at its martensite start temperature (temperature at which the transformation from austenite to martensite begins on cooling). During this austenite-to-martensite transformation, the two-way SMA actuator deforms toward the second trained or martensitic shape. With continued cooling, the two-way shape memory alloy eventually completes the austenite-to-martensite transformation at its martensite finish temperature (temperature at which the transformation from austenite to martensite finishes on cooling). It should be understood that the martensite start and finish temperatures and rate of the austenite-to-martensite transformation can vary depending on the particular application and its thermal environment, the composition of and particular SMA materials being used, and/or amount and rate of cooling or heat transfer from the two-way SMA actuator.
Cooling the two-way shape memory alloy can include passive cooling, active cooling, a combination thereof, etc. In one embodiment, the two-way shape memory alloy is passively cooled through heat exchange with its surrounding environment (e.g., structure, ambient atmosphere, etc.) once the supply of electrical power to the heating device is cutoff. Alternatively or additionally, the two-way shape memory alloy can be actively cooled, for example, if a higher rate of transformation to the martensitic state and shape is desired. By way of example, the two-way shape memory alloy can be actively cooled by circulating coolant over the two-way SMA actuator.
By way of further example, the two-way shape memory alloy can be actively cooled by supplying electrical power to a thermoelectric device having one side thermally coupled to the shape memory alloy. The thermoelectric device has the characteristic that heat flows from one side of the thermoelectric device to the other side. Accordingly, shape memory alloy can be cooled if it is thermally coupled to the cooled side of the thermoelectric device. Advanced thermoelectric devices are disclosed in
The system and methods disclosed above may be employed in an aircraft manufacturing and service method 200 as shown in
Each of the processes of method 200 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of venders, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.
As shown in
Apparatus and methods embodied herein may be employed during one or more of the stages of the production and service method 200. For example, components may be fabricated during production process 208 using the techniques disclosed herein. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the production stages 208 and 210, for example, by substantially expediting assembly of or reducing the cost of an aircraft 202.
According to a first aspect of the disclosure, there is provided a pre-form comprising tows made of thermoplastic material interwoven with tapes or wires made of shape memory alloy.
According to a further aspect of the disclosure, there is provided a system comprising a mandrel having an exterior surface and a pre-form in contact with said exterior surface and supported by said mandrel, wherein said pre-form comprises thermoplastic material and shape memory alloy.
Optionally, said pre-form comprises tows made of thermoplastic material interwoven with tapes or wires made of shape memory alloy.
Optionally, said pre-form comprises a first layer comprising shape memory alloy and a second layer comprising thermoplastic material without shape memory alloy, said first layer being disposed between said exterior surface of said mandrel and said second layer.
Optionally, the shape memory alloy of said first layer is in the form of a continuous sheet or a multiplicity of tapes or wires.
Optionally, said first layer comprises tows made of thermoplastic material interwoven with tapes or wires made of shape memory alloy.
According to a further aspect of the disclosure, there is provided an aerodynamic device comprising first and second skins, each of said first and second skins comprising shape memory alloy and thermoplastic material.
Optionally, said first skin comprises thermoplastic material and tapes or wires made of shape memory alloy material embedded in said thermoplastic material.
Optionally, said first skin is a lamination comprising an inner layer comprising shape memory alloy and an outer layer comprising thermoplastic material without shape memory alloy, said inner layer being disposed inside said outer layer.
Optionally, said inner layer comprises thermoplastic material and tapes or wires made of shape memory alloy at least partly embedded in the thermoplastic material of said inner layer.
Optionally, the aerodynamic device further comprises a first heating blanket thermally coupled to the shape memory alloy of said first skin and a second heating blanket thermally coupled to the shape memory alloy of said second skin.
Optionally, the shape memory alloy of said first skin comprises a first multiplicity of wires and the shape memory alloy of said second skin comprises a second multiplicity of wires, further comprising a first electrical conductor electrically connected to respective ends of said first multiplicity of wires and a second electrical conductor electrically connected respective ends of said second multiplicity of wires.
Optionally, the aerodynamic device further comprises an induction coil and a smart susceptor thermally coupled to the shape memory alloy of said first skin, wherein said smart susceptor is disposed relative to said induction coil such that eddy currents will be induced in said smart susceptor when said induction coil is activated to generate an alternating magnetic field.
Optionally, at least some of the shape memory alloy of said first skin and at least some of the shape memory alloy of said second skin has been trained to deform in a specified manner in response to being heated.
According to a further aspect, there is provided a method for fabricating a composite structure comprising:
Optionally, the method further comprises training at least some of the shape memory alloy incorporated in the composite structure.
Optionally, the mandrel is made of soluble material and separating the mandrel from the composite structure comprises solubilizing the soluble material of the mandrel.
According to the invention, there is provided a method for fabricating a composite structure comprising:
Optionally, the first layer of the pre-form comprises tows made of thermoplastic material interwoven with tapes or wires made of shape memory alloy.
Optionally, the mandrel is made of soluble material and separating the mandrel from the composite structure comprises solubilizing the soluble material of the mandrel.
Optionally, the method further comprises training at least some of the shape memory alloy incorporated in the composite structure.
While systems and methods for fabricating adaptive composite structures using SMA material have been described with reference to various embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the teachings herein. In addition, many modifications may be made to adapt the concepts and reductions to practice disclosed herein to a particular situation. Accordingly, it is intended that the subject matter covered by the claims not be limited to the disclosed embodiments.
In addition, the method claims set forth hereinafter should not be construed to require that the steps recited therein be performed in alphabetical order (any alphabetical ordering in the claims is used solely for the purpose of referencing previously recited steps) or in the order in which they are recited. Nor should they be construed to exclude any portions of two or more steps being performed concurrently or alternatingly.
As used in the claims, the term "inner layer" is not limited to being an innermost layer, but rather may also encompass an intermediate layer which is between an outermost layer and an innermost layer. Similarly, as used in the claims, the term "outer layer" is not limited to being an outermost layer, but rather may also encompass an intermediate layer which is between an outermost layer and an innermost layer. When used in conjunction, the "inner layer" is a layer which is inside the "outer layer".
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