Thesis (DTech (Mechanical Engineering))--Peninsula Technikon, 2004. / Engineers and Technologists have always been identified as those individuals that put into practice the theories developed by scientists and physicists to enhance the lives of human beings. In the same spirit as those that came before, this thesis describes the development of a computational engineering tool that will aid Engineers and Technologists to design smart or intelligent structures comprising of NiTi shape memory alloy rods for actuation purposes. The design of smart actuators consisting of NiTi shape memory alloy structural members will be beneficial to industries where light weight, compactness, reliability and failure tolerance is of utmost importance. This is mainly due to the unique material responses exhibited by this smart material. The shape memory effect, one of these material responses consists out of two stages: a low temperature load induced phase transformation causing a macroscopic deformation (either extension, contraction, etc.) also known as quasi-plasticity; and a high temperature phase transformation that erases the low temperature macroscopic deformation and reverts the material to some predefined geometry. When designing actuators consisting of this smart material, the quasi-plastic material response produces the actuation stroke while the high temperature phase transformation produces the actuation force. The successful engineering design of smart structures and devices particularly suited for applications where they operate in a capacity, as actuators harnessing the shape memory effect are dependent on a few important factors. These include the engineers familiarity with the type of smart material used, the availability of sound experimental data pertaining to the complex material responses exhibited by the smart material, the engineers level of proficiency with existing constitutive models available to simulates these material responses, and the engineers knowledge of simulation tools consisting of a suitable control algorithm fo~ the modeling of not only the device or structure itself but also the actuator involved in the design.

Shape memory alloys (SMAs) exhibit unique combination of structural and functional properties and hence have a variety of current and potential applications. The mechanical behaviour of SMAs, in particular the influence of processing on the microstructure, which in turn influences the performance of the alloy, mechanical properties at the nano-scale, and under cyclic loading conditions, are of great current interest. In this thesis, specific issues within each of these broad areas are examined with a view to suggest further optimize/characterize SMAs. They are the following: (a) For thermo-mechanical secondary processing of SMAs, can we identify the optimum combination of temperature- strain rate window that yields a desirable microstructure? (b) How can indentation be used to obtain information about functional properties of shape memory alloys so as to complement traditional methods? (c) How can the information obtained from indentation be utilized for the identification of the alloy composition that yields a high temperature SMA through the combinatorial diffusion couple approach? Towards achieving the first objective, we study the hot deformation behavior of a cast NiTi alloy with a view of controlling the final microstructure. The “processing maps” approach is used to identify the optimum combination of temperature and strain rate for the thermomechanical processing of a SMA system commonly used in actuators applications (NiTiCu). Uniaxial compressions experiments are conducted in the temperature range of 800- 1050 °C and at strain rate range of 10-3 and 102 s-1. 2-D power dissipation efficiency and instability maps are generated and various deformation mechanisms, which operate in different temperature–strain rate regimes, are identified with the aid of these maps. Complementary microstructural analysis of specimens (post deformation) is performed with the help of electron backscattered diffraction (EBSD) analysis to arrive at a processing route which produces stress free grains. A safe window suitable for industrial processing of this alloy which leads to grain refinement and strain-free grains (as calculated by various methods of misorientation analysis representation) is suggested. Regions of the instability (characterized by the same analysis) result in strained microstructure, which in turn can affect the performance of the SMA in a detrimental manner. Next, to extract useful information from indentation responses, microindentation experiments at a range of temperatures (as the shape memory transformation is in progress) are conducted underneath the Vickers indenter. SME was observed to cause a change in the calculated recovery ratios at temperatures above As. Spherical indentation of austenite and martensite show different characteristics in elastic and elasto- plastic regimes but are similar in the plastic regime. NanoECR experiments are also conducted under a spheroconical indenter at room temperature, where the resistance measured is observed to increase during the unloading of room temperature austenite SMA. This is a signature of the reverse transformation back to austenite during the withdrawal of the indenter. Lastly, recovery ratios are monitored in the case of a NiTiPd diffusion couple before and after heat treatment at different temperature intervals using non- contact optical profilometry. The recovery ratio approach is successfully used to determine the useful temperature and %Pd range for a potential NiTiPd high temperature SMA. The method makes high throughput identification of high temperature shape memory alloys possible due to promising alloy compositions being identified at an early stage.

Le titane, comme ses alliages, présente des caractéristiques remarquables qui peuvent être modulées du fait des nombreuses microstructures qu’il est possible d’obtenir. Grâce à cette grande variété, le titane et ses alliages possèdent un grand nombre de propriétés. Parmi les plus intéressantes, on peut citer leur résistance à la corrosion, leur biocompatibilité, mais aussi leurs excellentes propriétés mécaniques (résistance, ductilité, ténacité, fluage…). Pour toutes ces raisons, l’attrait pour les alliages de titane n’a cessé de croître dans de nombreux secteurs. En effet ils sont maintenant largement utilisés dans les industries aéronautique et chimique, mais aussi l’architecture, le naval, l’industrie automobile, le sport ou encore la médecine. La nanoindentation est utilisée couramment de nos jours pour déterminer les propriétés mécaniques locales des matériaux. Elle permet notamment de caractériser des alliages métalliques possédant une microstructure polycrystalline. La taille de l’indenteur en nanoindentation étant faible (de quelques micromètres à quelques dizaines de micromètres), cette technique est idéale pour caractériser les propriétés mécaniques de surface des différents grains d’un matériau. Elle permet notamment de mesurer simultanément la dureté et le module d’élasticité. Si les essais de nanoindentation sont associés à un banc motorisé X-Y, une matrice étendue d’indents peut être réalisée avec un pas de quelques micromètres. Grâce à cette technique et dans le cadre de ce travail de thèse, nous avons réalisé dans un premier temps des cartographies de dureté et de module d’élasticité (HIPF et EIPF). Dans un second temps, nous avons évalué des propriétés non-conventionnelles d’alliages de titane, telles que l’effet mémoire de forme et la superélasticité. Dans la première partie de l’étude, la nanoindentation a été corrélée à l’EBSD (diffraction des électrons rétro-diffusés) afin d’identifier la relation entre l’orientation cristallographique d’un grain et ses propriétés mécaniques. L’étude a été menée sur les alliages de composition Ti-30Nb et Ti-27Nb (%at) de structure cubique centrée (phase ), et sur le titane de pureté commerciale T40, de structure hexagonale compacte (phase ). Dans la seconde partie de l’étude, la nanoindentation a été utilisée pour mesurer l’effet mémoire de forme (SM) et la superélasticité (SE) de différents alliages de titane à travers une large gamme de profondeur d’indentation. La mesure de ces propriétés non-conventionnelles a été réalisée à partir de l’étude des courbes charge-déplacement obtenues pour chaque essai d’indentation. L’amplitude de l’effet SE et SM a été caractérisée par des ratios de hauteur et de travail déterminés par l’étude des courbes de nanoindentation ainsi que des profils AFM réalisés au microscope à force atomique. / Titanium and titanium alloys presents remarkable characteristics which can be modulated due to the many different microstructures that is possible to obtain. Thanks to this huge variety, titanium and its alloys can exhibit many properties. Among the most interesting, there may be mentioned their corrosion resistance, biocompatibility, but also their excellent mechanical properties (strength, ductility, toughness, creep…). For all these reasons, interest for of titanium alloys has been growing in many areas. Indeed they are now widely used in the aerospace and chemical industries, but also in architecture, naval, automotive, sports or medicine. Nanoindentation is commonly used nowadays to determine local mechanical properties of materials. For example, this technique allows the characterization of metallic alloys having a polycrystalline microstructure. The size of the indenter in nanoindentation being small (few microns to few tens microns), and consequently this technique is ideal for characterizing the surface mechanical properties of different grains of a material. It allows simultaneous measurement of the hardness and the elastic modulus. If nanoindentation tests are associated with a XY motorized test bed, a wide array of indents can be achieved with a step of few micrometers. Thanks to this technique and as part of this thesis, we have realized at first hardness and elastic modulus mapping (HIPF and EIPF). In a second time, we have evaluated unconventional properties of titanium alloys, such as shape memory effect and superelasticity. In the first part of the study, nanoindentation was correlated with EBSD (Electron backscattered diffraction) to identify the relationship between the crystallographic orientation of a grain and its mechanical properties. The study was conducted on the Ti-30Nb and Ti-27Nb (at.%) alloy compositions having a bodycentered cubic structure ( phase), and the commercially pure titanium (CP-Ti) having a hexagonal close packed structure ( phase). In the second part of the study, nanoindentation was used to measure the shape memory effect (SM) and the superelasticity (SE) of various titanium alloys through a range of indentation depth. The measurement of these unconventional properties was performed from the study of load-displacement curves for each indentation test. The magnitude of the SE and SM effect was characterized by depth and work ratios determined from the study of nanoindentation curves and AFM profiles.

NiTi (also known as Nitinol) is an almost equiatomic alloy of nickel and titanium and has many applications in various industries, such as biomedical, automotive, and aerospace. NiTi shape memory alloys undergo martensitic phase transformations under both thermal and mechanical loading and exhibit unique properties, such as superelasticity (SE) and shape memory effects (SME). Modeling the fatigue behavior of this alloy is very challenging due to the unique mechanical response of the material. Moreover, there are very limited studies on the fatigue behavior of this alloy under more realistic loading conditions, such as variable amplitude loading and multiaxial loading. In this study, strain-controlled cyclic experiments have been conducted in different conditions to study the variable amplitude fatigue behavior of superelastic NiTi. Nonzero mean strain/stress behavior of superelastic NiTi is investigated, and it is demonstrated that the classical fatigue models for mean strain/stress correction do not appropriately model the nonzero mean strain/stress fatigue behavior of superelastic NiTi. It is shown that, despite common metals (e.g., steel, aluminum, and titanium alloys), mean strain also affects the fatigue behavior of superelastic NiTi, as the resulting mean stress does not fully relax under cyclic load. Two energy-based fatigue models have been proposed based on the results in this study and provide acceptable correlation with experimental observations. The models proposed in this research, account for the effects of mean strain/stress and variations in cyclic deformation. The variations in the cyclic deformation can be due to several factors, such as slight changes in chemical composition, heat treatment processes, texture, etc. The predicted fatigue lives using the proposed fatigue model fall within scatter bands of 1.5 times the experimental life for constant amplitude loading. Analyses also show that the proposed total fatigue toughness parameter, ΣWt, together with the Rainflow cycle counting technique can accurately predict the fatigue life under more realistic loading condition, such as two-step (i.e. high-low and low-high) and variable amplitude load-paths.

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This dissertation presents a one-dimensional thermomechanical constitutive model for shape memory alloys based on basic concepts of thermodynamics and phase transformation kinetics. Compared with other developed constitutive relations, this thermomechanical constitutive relation not only reflects the physical essence of shape memory alloys, i.e., the martensitic phase transformation involved, but also provides an easy-to-use design tool for engineers. It can predict and describe the behavior of SMA quantitatively. A multi-dimensional constitutive relation for shape memory alloys is further developed based on the one-dimensional model. It can be used to study the mechanical behavior including shape memory effect of complex SMA structures that have never been analytically studied, and provide quantitative analysis for many diverse applications of shape memory alloys. A general design method for shape memory alloy actuators has also been developed based on the developed constitutive relation and transient thermal considerations. The design methodology provides a quantitative approach to determine the design parameters of shape memory alloy force actuators, including both bias spring SMA force actuators and differential SMA force actuators. / Ph. D.

Shape memory alloys (SMA) have the unique ability to recover large strains and generate large recovery stresses via a repeatable martensitic transformation. Stress-strain and shape memory effect characteristics are needed in order to develop SMA force actuator design methods. Moreover, constitutive models able to quantitatively predict these characteristics and thus be useful as engineering design tools are also needed. An experimental apparatus designed to characterize the mechanical behavior of SMA was built and utilized. The apparatus is used specifically to gather stress-strain and shape memory effect characteristics from nitinol wire whereby mechanical properties associated with the material are determined. Phenomena such as the R-phase and stress induced martensite serration are investigated. A one-dimensional constitutive model is presented that quantitatively predicts stress-strain and shape memory effect behavior and was developed with the intention of being an engineering design tool for SMA force actuators. Experimental stress-strain and shape memory effect results are compared against that predicted by the model with the intention of verifying the model. The model displays the ability to predict stress-strain behavior that is in good quantitative agreement with experiment. The model also displays the ability to predict hysteric shape memory effect behavior for free, controlled, and restrained recovery cases of selected prestrains that is in good quantitative agreement with experiment. The model is unable to predict shape memory effect behavior such as the R-phase. Demonstrating the ability to experimentally investigate a constitutive model will hopefully inspire further combined experimental and theoretical SMA research. / Master of Science

The design of unmanned underwater vehicle (UUV) was inspired by the form and functionality of Jellyfish. These natural organisms were chosen as bio-inspiration for a multitude of reasons including: efficiency, good room for payload, and a wide range of sizes and morphology. Shape memory alloy (SMA) actuators were selected as the primary source of actuation for the propulsion of the artificial jellyfish node. These actuators offer high power density which enables a compact system size and silent operation which is preferred for surveillance.  SMA wires mimic the form and function of natural muscles; allowing for a wider range of applications than conventional actuators. Commercial SMA wires (100 um in diameter) can exhibit a 4% deformation of the initial actuator length with a blocking stress of over 200 MPa. The deformation of SMA wire is not enough to mimic the bell contraction of jellyfish. In order to resolve this problem, a beam-shape composite actuator using SMA wires as the active component, termed as BISMAC, was designed to provide large curvature. The BISMAC design was inspired by rowing jellyfish bell contraction. Characterization of maximum deformation in underwater conditions was performed for different actuator configurations to analyze the effect of design parameters that include silicone thickness, flexible steel thickness and distance between SMA and flexible steel. A constant cross-section (CC) BISMAC of 16 cm in length was found to achieve deformation with a radius of curvature of 3.5 cm. Under equilibrium conditions, the CC-BISMAC was found to achieve 80% of maximum deformation consuming 7.9 J per cycle driven at 16.2 V/0.98 A and frequency of 0.25 Hz. Using the a developed analytical model, an actuator design was fabricated mimicking the maximum deformation profile of the A. aurita. The optimized AA-BISMAC achieved a maximum curvature of 0.428 1/cm as compared to 0.438 1/cm for the A. aurita with an average squared root error of 0.043 (1/cm), 10.2% of maximum A. aurita curvature.   BISMAC actuators are unidirectional flexible actuators capable of exhibiting high curvature. To extend the application range of these actuators, they were modified to achieve bidirectional deformation. The new bidirectional actuators termed as "BiFlex" actuators had the capability to achieve large deformation in two directions. The FlexLegs consist of six segments which can be actuated individually. Two different sets of legs were constructed to determine the effect of size. The small legs measured 35.8 mm in height and 63.2 mm in width and the large legs were 97.4 mm in height and 165.4 mm in width. The small FlexLegs achieved a maximum deformation of 12 % and 4 % in the x- and y-direction respectively using a power of 0.7 W while producing a maximum force of 0.023 N. They were also able to withstand a load of 1.18 N. The large FlexLegs had a maximum deformation of 57 % and 39 % in the x- and y-direction respectively using a power of 3 W while producing a force of 0.045 N. They were able to withstand a load of 0.25 N. The legs were also able to perform several walking algorithms consisting of stepping, crabbing and yawing. In order to reduce the power consumption and contraction time of SMA wires, a feedback control scheme using wire resistance was developed. The controller required the knowledge of threshold resistance and safe current inputs which were determined experimentally. The overheating effect of SMA wires was analyzed for BioMetal Fiber (BMF) and Flexinol 100 "m diameter wires revealing an increase in resistance as the wires overheated. The controller was first characterized on a SMA wire with bias spring system for a BMF 100 using I_hi=0.5 A and I_low=0.2 A, where hi corresponds to peak current for fast actuation and low corresponds to the safe current which prevents overheating and maintains desired deformation. A contraction of 4.59% was achieved in 0.06 s using the controller and the deformation was maintained for 2 s at low current. The BISMAC actuator was operated using the controller with I_hi=1.1 A and I_low=0.65 A achieving a 67% decrease in contraction time compared to using a constant driving current of I_low=0.2 A and a 60% decrease in energy consumption compared to using constant I_hi=0.5 A while still exceeding the contraction requirements of the Aurelia aurita. Two fundamental parameters at the composition level were associated with the power consumption of SMA: i) martensite to austentite phase transition temperature and ii) thermal hysteresis. Ideally, one would like to reduce both these quantities and for this purpose an equiatomic Ni-Ti alloy was modified with Cu. Replacing nickel with 10 at% copper reduces the thermal hysteresis by 50% or more. For Ni-Ti alloys with nickel content greater than 50 at%, transition temperature decreases linearly at a rate of 100 "C/Ni at%. Given these two power reducing factors, an alloy with composition of Ni40+xTi50-xCu10 was synthesized with x = 0, ±1, ±2, ±3, ±4, ±5. Metal powders were melted in an argon atmosphere using an RF induction furnace to produce ingots. All the synthesized samples were characterized by differential scanning calorimetric (DSC) analysis to reveal martensite to austenite and austenite to martensite transition temperatures during heating and cooling cycles respectively. Scanning electron microscopy (SEM) was conducted to identify the density and microstructure of the fractured samples. The results show the possibility of achieving low power consuming high performance SMAs. Using the BISMAC actuator and feedback control system, a robotic jellyfish called Robojelly that mimics the morphology and kinematics of the Aurelia aurita species was created. A systematic fabrication technique was developed to replicate the essential structural features of A. aurita. Robojelly's body was fabricated from RTV silicone having a total mass of 242 g and bell diameter of 16.4 cm. Robojelly was able to generate enough thrust in static water conditions to propel itself and achieve a proficiency of 0.19 s-1 while the A. aurita achieves a proficiency of around 0.25 s-1. A thrust analysis based on empirical measurements for natural jellyfish was used to compare the performance of the different robotic configurations. The configuration with best performance was a Robojelly with segmented bell and a passive flap structure. Robojelly was found to consume an average power on the order of 17 W with the actuators not having fully reached thermal steady state. A comparative kinematics analysis was conducted between a natural Aurelia aurita and Robojelly. The resistance feedback controller was implemented to tailor the deformation profile of BISMAC actuators embedded in Robojelly. Robojelly's performance was quantified in terms of thrust production and power consumption during vertical swimming experiments. A maximum average instantaneous thrust production of 0.006 N was achieved at a driving current (Ihi) of 1.5 A with 35% duty cycle. Rapid heating of SMA wires was found to reduce power consumption and increase thrust. The bell kinematic analysis revealed resemblance and differences in bell deformation trajectories of the biomimetic and natural jellyfish. The inflexion point of the A. aurita was found to convert an inner bell trajectory into an outer one during contraction which assists the thrust production. A biomimetic robot inspired by Cyanea capillata, termed as "Cyro", was developed to meet the functional demands of underwater surveillance in defense and civilian applications. The design of Cyro required kinematics of large C. capillata which are elusive creatures. Obtaining accurate kinematic data of animals is essential for many biological studies and bio-inspired engineering applications. Many animals such as the C. capillata however, are either too large or too delicate to transport to controlled environments where accurate kinematic data can easily be obtained. Often, in situ recordings are the only means available but are often subject to multi-axis motion and relative magnification changes with time, which lead to large discrepancies in animal kinematics. In Chapter 5, techniques to compensate for magnification and body rotation of animal footage were developed. A background reference point and animal dimensions were used to account for magnification. A linear fit of body points were used to measure body rotation. These techniques help resolve animal kinematics from in situ video footage. The techniques were applied to a large jellyfish, Cyanea capillata, swimming in ocean waters. The bell kinematics were captured by digitizing exumbrella profiles for two full swimming cycles. Magnification was accounted for by tracking a reference point on the ocean floor and by tracking the C. capillata exumbrella arclength in order to have a constant scale through the swimming cycles. A linear fit of the top bell portion was used to find the body angle with respect to the camera coordinate system. Bell margin trajectories over two swimming cycles confirm the accuracy of the correction techniques. The corrected profiles were filtered and interpolated to provide a set of time-dependent points along the bell. The ability to use in situ footage with significant multi-axis motion provides an opportunity to analyze previously impractical footage for gaining a better understanding of large or delicate organisms. The swimming kinematics of the C. capillata were analyzed after extracting the required kinematics from the in situ video. A discrete model of the exumbrella was developed and used to analyze the kinematics. The exumbrella discretization was done using three different methods. The first method consists of analyzing the animal anatomy for structural and mechanical features. The second method consists of analyzing the bell kinematics for areas of highest deformation over time. The third method consists of optimizing node locations that can provide minimal error with comparison to the digitized profiles. Two kinematic models of the C. capillata swimming motion were developed by fitting Fourier series to the discretized segments and angles formed by each segment. The four-segment anatomical kinematic model was used to analyze the bell kinematics of the C. capillata. It was found that the bell does not deform uniformly over time with segments lagging behind others. Hysteresis between contraction and relaxation was also present through most of the exumbrella. The bell margin had the largest hysteresis with an outer path during contraction and inner path during relaxation. The subumbrella volume was approximated based on the exumbrella kinematics and was found to increase during contraction. Cyro was designed to mimic the morphology and swimming mechanism of the natural counterpart. The body of the vehicle consists of a rigid support structure with linear DC motors which actuate eight mechanical arms. The mechanical arms in conjunction with artificial mesoglea create the hydrodynamic force required for propulsion. The full vehicle measures 170 cm in diameter and has a total mass of 76 kg. An analytical model of the mechanical arm kinematics was developed. The analytical and experimental bell kinematics were analyzed and compared to the C. capillata. Cyro reached the water surface untethered and autonomously from a depth of 182 cm in five actuation cycles. It achieved an average velocity of 8.47 cm/s while consuming an average power of 70 W. A thrust stand was developed to calculate the thrust directly from a single bell segment yielding an average thrust of 27.9 N for the whole vehicle. Steady state velocity during Cyro's swimming test was not reached but the measured performance during its last swim cycle resulted in a cost of transport of 10.9 J/kg m and total efficiency of 3%. It was observed that a passive flexible margin or flap, drastically increases the performance of the Robojelly. The effects of flap length and geometry on Robojelly were analyzed using PIV. The flap was defined as the bell section which is located between the flexion point and bell margin. The flexion point was established as the location where the bell undergoes a significant change compliance and therefore in slope. The flap was analyzed in terms of its kinematics and hydrodynamic contribution. An outer trajectory is achieved by the flap margin during contraction while an inner trajectory is achieved during relaxation. The flap kinematics was found to be replicable using a passive flexible structure. Flaps of constant cross section and varying lengths were put on the robotic vehicle to conduct a systematic parametric study. Robojelly's swimming performance was tested with and without a flap. This revealed a thrust increase 1340% with the addition of a flap.  Velocity field measurements were performed using planar Time Resolved Digital Particle Image Velocimetry (TRDPIV) to analyze the change in vortex structures as a function of flap length.  The robot input parameters stayed constant over the different configurations tested thus maintaining a near constant power consumption. Non-dimensional circulation results show a dependence on flap kinematics and geometry. The robot was approximated as a series of pitching panels circularly oriented around its apex. The first circulation peak of the pitching panel approximation revealed a normalized standard deviation of 0.23. A piston apparatus was designed and built to test different flexible margin configurations. This apparatus allow the isolation of the flap parameters and remove the uncertainties coming from the robotic vehicle. / Ph. D.