Published Article / The link from medical scan images through data manipulation to additive manufacturing is well established. Various types of software are used to deliver the required .STL file(s). Often, the data manipulation will require the generation of new shapes around existing geometry, e.g. an implant that will replace missing bone tissue. This paper reports exploratory work undertaken to assess the feasibility of using haptic modelling and "virtual sculpting" software to generate novel designs of vertebrae implants for correction of spinal curvature. .STL data of several vertebrae, originating from CT scans, was imported into the Freeform system from SensAble technologies. It was used to create immutable "bucks" around which the user "sculpted" three-dimensional implant geometries. It must be noted that the designs have not been medically assessed and were for demonstration purposes only. However, the process route followed did prove to be feasible and offered some particular advantages, e.g. a precise fit between the implant and the vertebra and the possibility of enabling the direct intervention of medics in the implant design process.

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Ni-Mn-Ga is a ferromagnetic shape memory alloy that can be used for future sensors and actuators. It has been shown that magnetic field can induce phase transformation and consequently large strain in stoichiometric Ni2MnGa. Since then considerable progress has been made in understanding the underlying science of shape memory and ferromagnetic shape memory in bulk materials. Ni-Mn-Ga thin films, however is a relatively under explored area. Ferromagnetic shape memory alloy thin films are conceived as the future MEMS sensor and actuator materials. With a 9.5 percent strain rate reported from magnetic reorientation, Ni-Mn-Ga thin films hold great promise as actuator materials. Thin films come with a number of advantages and challenges as compared to their bulk counterparts. While properties like mechanical strength, uniformity are much better in thin film form, high stress and constraint from the substrate pose a significant challenge for reorientation and shape memory behavior. In either case, it is very important to understand their behavior and examine their properties. This thesis is an effort to contribute to the literature of Ni-Mn-Ga thin films as ferromagnetic shape memory alloys. The focus of this project is to develop a recipe for fabricating NiMnGa thin films with desired composition and microstructure and hence unique properties for future MEMS actuator materials and characterize their properties to aid better understanding of their behavior. In this project NiMnGa thin films have been fabricated using magnetron sputtering on a variety of substrates. Magnetron sputtering technique allows us to tailor the composition of films which is crucial for controlling the phase transformation properties of NiMnGa films. The composition is tailored by varying several deposition parameters. Microstructure of the films has been investigated by X-ray diffraction (XRD) and transmission electron microscopy (TEM) techniques. Mechanical properties of as-deposited films have been probed using nano-indentation technique. The chemistry of sputtered films is determined quantitatively by wavelength dispersive X-ray spectroscopy (WDS). Phase transformation is studied by using a combination of differential scanning calorimetry (DSC), in-situ heating in TEM and in-situ XRD instruments. Magnetic properties of films are examined using superconducting quantum interface device (SQUID).

Shape memory alloys are new, functional materials used in actuator applications with their high power to weight ratio. The high strength or displacement usage of shape memory alloys makes them suitable for direct drive applications, which eliminate use of power transmission elements. The aim of this research is to develop the methodology and the necessary tools to design and produce linear shape memory alloy actuators to be used in missile systems, space applications, and test equipments. In this study, the test apparatus designed and built to characterize shape memory alloy thin wires is described, and then the characterization tests, modeling and control studies performed on a wire are explained. In the control studies, displacement control through strain, resistance and power feedback is investigated and different control strategies (proportional-integral, proportional-integral with feedforward loop, and neural network) are employed. The results of the characterization tests, simulations and experiments are all presented in graphical and tabular form. From the results it is concluded that through careful characterization, the behavior of SMA wire can be closely approximated through models which can be used effectively to test various control strategies in simulations. Also, satisfactory position control of SMA wires can be achieved through both classical and NN control strategies by using appropriate feedback variables and power is found to be a viable feedback variable. Lastly, a linear SMA wire actuator is designed as a case study. The actuator prototype is produced, suitable control strategies are applied and actuator is experimented to validate the theoretical assumptions. The actuator developed through this work is a technology demonstration and shows that shape memory alloy elements can be utilized in several defense and space applications contracted to T&Uuml / BiTAK-SAGE as well as certification test equipments. The development of shape memory alloy actuators that can be used in defense and later in aeronautical/space applications is a critical research and development project for national defense industry.

This work investigates the use of shape memory alloys (SMAs) for vibration isolation and damping of mechanical systems. The first part of this work evaluates the nonlinear dynamics of a passive vibration isolation and damping (PVID) device through numerical simulations and experimental correlations. The device, a mass connected to a frame through two SMA wires, is subjected to a series of continuous acceleration functions in the form of a sine sweep. Frequency responses and transmissibility of the device as well as temperature variations of the SMA wires are analyzed for the case where the SMA wires are pre-strained at 4.0% of their original length. Numerical simulations of a one-degree of freedom (1-DOF) SMA oscillator are also conducted to corroborate the experimental results. The configuration of the SMA oscillator is based on the PVID device. A modified version of the constitutive model proposed by Boyd and Lagoudas, which considers the thermomechanical coupling, is used to predict the behavior of the SMA elements of the oscillator. The second part of this work numerically investigates chaotic responses of a 1- DOF SMA oscillator composed of a mass and a SMA element. The restitution force of the oscillator is provided by an SMA element described by a rate-independent, hysteretic, thermomechanical constitutive model. This model, which is a new version of the model presented in the first part of this work, allows smooth transitions between the austenitic and the martensitic phases. Chaotic responses of the SMA oscillator are evaluated through the estimation of the Lyapunov exponents. The Lyapunov exponent estimation of the SMA system is done by adapting the algorithm by Wolf and co-workers. The main issue of using this algorithm for nonlinear, rateindependent, hysteretic systems is related to the procedure of linearization of the equations of motion. The present work establishes a procedure of linearization that allows the use of the classical algorithm. Two different modeling cases are considered for isothermal and non-isothermal heat transfer conditions. The evaluation of the Lyapunov exponents shows that the proposed procedure is capable of quantifying chaos in rate-independent, hysteretic dynamical systems.

This work details an investigation into the production of porous shape memory alloys (SMAs) via hot isostatic press (HIP) from prealloyed powders. HIPing is one of three main methods for producing porous SMAs, the other two are conventional sintering and selfpropagating hightemperature synthesis (SHS). Conventional sintering is characterized by its long processing time at near atmospheric pressure and samples made this way are limited in porosity range. The SHS method consists of preloading a chamber with elemental powders and then initiating an explosion at one end, which then propagates through the material in a very short time. HIPing provides a compromise between the two methods, requiring approximately 5 hours per cycle while operating in a very controlled environment. The HIPing method gives fine control of both temperature and pressure during the run which allows for the production of samples with varying porosity as well as for finetuning of the process for other characteristics. By starting with prealloyed powder, this study seeks to avoid the drawbacks while retaining the benefits of HIPing with elemental powders. In an extension of previous work with elemental powders, this study will apply the HIP method to a compact of prealloyed powders. It is hoped that the use of these powders will limit the formation of alternate phases as well as reducing oxidation formed during preparation. In addition, the nearspherical shape of the powders will encourage an even pore distribution. Processing techniques will be presented as well as a detailed investigation of the thermal and mechanical properties of the resulting material.

Smart materials and structures systems are increasingly being developed to handle more complex problems. One of the main research schemes is the augmentation of the control authority of the smart actuators used in such systems. The augmentation can be obtained by constructing hybrid and multi- smart materials actuator systems and/or by the optimization of the location and orientation of those actuators. In the first part of this study, the alteration of the natural frequency of composite structures using Nitinol-based Shape Memory Alloy (SMA) wires will be presented using the analyses of strain energy perturbations on a plate. These governing strain equations were solved analytically and numerically to show the effect of point forces acting in a distributive manner and the subsequent effect it has on the plate's stiffness and hence it's natural frequency. In the second part of the thesis, a more complex loading condition is considered to investigate piezoceramic actuator control authority in relation to wing flutter control. The advancement in the application of active material induced-strain actuation such as piezoelectric materials in suppression of structural vibrations drew wide interest in its use for wing flutter control. Higher flutter speed and hence wider operating envelope was achieved by delaying the coalescence of the eigenvalues for plunge and twist modes. . This delay is obtained by adding more strain energy to the system as a result of the activation of the piezoelectric actuators. Most of the studies done were by controlling the plunge/bending motion, where the piezoelectric actuators are bonded longitudinally to produce bending moments. In this study, the control of the pitch/twisting motion was investigated and it showed better control of flutter by using simultaneous multi-actuations compared to single piezo actuations. It was shown that within the scope of the angular orientations of the piezoelectric patches investigated in this study, piezoelectric patches oriented about +150 from the beam's longitudinal ax is resulted in the most optimal piezo-configuration. This was corroborated by both the numerical flutter speed and actuator moment evaluations. In addition, the orientation of the piezoelectric patches was shown to significantly affect the pitch angle of the beam relative to each other. The damping ratio was also investigated and this showed greater instability for piezoelectric patches oriented at negative angles, thus further supporting the finding of the aforementioned optimal orientation of +150. These findings confirmed the dominance of the base (closest to the fixed portion of the beam) piezo when actuated with other piezos.

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