Manuel, Michele

Wallace, Terryl

Wright, Clara M.

NASA Technical Reports Server

NASA Aeronautics Research Institute FY12 Seedling Phase I Technical Seminar 
NARI • 
Thermo-mechanical evaluation of self-
healing metallic structures for aerospace 
vehicles utilizing shape memory alloys 
Investigators: 
M. Clara Wright, NASA KSC1 
Michele Manuel, University of Florida2 
Terryl Wallace, NASA LaRC3 
Team members: Charles Fisher2, Glenn Bean2, 0 
Jeff Sampson1, Thad Johnson1, Roy Kin 
Andy Newman! 
https://ntrs.nasa.gov/search.jsp?R=20140002388 2019-08-29T15:03:13+00:00Z
Outline 
NARI • 
•The innovation: SMASH Technology 
•Liquid-Assisted Self-Healing approach 
•Impact of the innovation 
•Results of the seedling Phase I effort 
•Distribution/Dissemination 
•Future Work 
July 9-11, 2013 
Shape Memory Alloy Self-Healing 
(SMASH} Technology 
NARI • 
• Designing and testing an aeronautical 
lightweight structural alloy with self-
repairing capabilities 
- Materials system can self-repair em-long 
cracks 
• Investigation focused on self-repair of fatigue 
cracks 
- Aluminum alloy matrix reinforced with high-
strength shape memory alloy (SMA) elements · 
· - Thermodynamic approach to design matrix 
alloy with pre-determined fraction of low 
melting eutectic phase 
June 5-7, 2012 
Liquid-Based Self-Healing of Metal-Metal 
Composites 
NARI • 
• Clamping force from the SMA wires 
• Partial liquefaction of the matrix 
a 
tri -~ 
Sh p 
mory 
AJioy 
(SMA 
r=T 
I 
~.::;..;:...:.;...=..:.m:.:.;:;o .... ry I = l = 
Cr \ 1,4 
\ 
Loe I Stf'i Indue d 
Tr form t on of S A 
'J = I 
t 
Cr e 
H ling 
• 
.: ,. ~ • • 
,• 
• 
i• 
• 
~ ~ ~ ~ 
I• • i• • 
• • le• •. • ~ 
" 
'~----~lr· ----==~==~~-
Manuel, M. V, Principles of Self-Healing in Metals and Alloys: An Introduction, Chapter~ .• "'!"!1'! .. ,.. 
Design Strategies and Applications, Ghosh, S. K. , Ed. Kfley: 
June 5-7, 2012 NASA Aeronautics Mission Directorate FYll Seedling l'na·~·'•·c•~ 
-
Liquid-Based Healing History 
NARI • 
• 
~ 
" ... 
" .... 
Healing of em-long cracks has been achieved in a 
proof-of-concept Sn-Bi matrix reinforced with Ni-Ti 
SMA wires 
Atomic Percen t Bismu t h 
20 :10 •o 110 eo ?o eo 
~Sn-21 wt% Bi 
L 
00 100 
Healing treatment: 20% 
liquid in matrix 
Post heal: 95% strength 
recovery {UTS) 
s1te 
.., l!IO 
80 
70 
60 
L. 
.. 
a. 
E 
., 
1-
100 
I 
I 
. I 
13"C L -------------__ J. ___ ---------- -~----------------------------------.--------
0 J::::-iaSn,) 1 I I I I I I I 
0 tO 20 30 40 $0 80 ?0 80 00 100 
Sn Weigh t Percent Bismuth Bi 
l so 
~ 
-;; 40 
~ 30 heal 
~ 
20 
10 
0 
0 0.02 
Manuel, eta/, "Design Considerations for Matrix Compositions in Sfllf·H••M :'IMIJ 
3rd International Conference on Self-Healing Materials; Jun9 
- 39 (31 
- C39 (3)H .. I 
0 .04 
June 5-7, 2012 NASA Aeronautics Mission Directorate FY11 Seedling Ph:ac:D:\ 
Knowledge Gap 
NARI • 
• POC material showed liquid-assisted self-
repair of overload cracks 
-Will self-healing work with a higher strength 
structural material? 
-Will liquid-assisted self-repair work for repairing 
fatigue cracks? 
- How is fatigue life affected by this technolotJ~""""' 
June 5-7, 2012 
Applications 
NARI • 
• Aerospace-grade aluminum materials subject to cyclic loading are 
susceptible to fatigue failure, sometimes catastrophic, at loads 
well below yield strength. 
• Wrought and cast AI alloys used throughout aircraft: 
Upper Wing Skin 
Baseline: 7055-T7751 . 7055-T7951 
New Products: 7255-T792 
7255 -T7751 . AI·LI UW-P2 
Integral Spars/Ribs 
Baseline: 7085-T7651 , 7050!7010-T7651 , 
7150-T7751 
New Products: 2397-T87. 
7085-T7451 , C85T-T7X 
Al-LI-TP-1, Al-lo-TP-2 
Internal Structure of Fuselage 
Baseline: 7050!701 017040-T7 451 , 7150-T7751 
Fuselage Skin/Stringers/Frames 
Baseline: Alc.2524-T3 Skin, Alc.6013-T6 HOT Skin. 
New Products : Al-U 2060-T8E30 Skon , 7055-T762 
(Stnngers/Fmmes) 
Lowtr Wing Skin 
Baselone: 2024-T351 , 2324-T39 
New Products: 2624-T351 , 2624-T39 
Al-Li 2199-T86. AI-U 2060-T8E86 
Green = Commercial 
New Products: AI-Li 2397-T87, AI-Li 2099-T86, 7085-T7451 
C85T-T7X. Al-LI2099-TBHS, N -lo-TP-1, AI-Li-TP-2 
Blue = Under Development 
Upper Wing Stringers 
Baseline: 7055-T77511 , 7055-T79511 
New Products: AI-Li 2099-T83, 
AI-Lo 2055-TBE83 
Floor Beams/Seat Tracks 
Baseline: 2099-T83, 7075f7175-T795 
New Products: 7055-T76511 , 
AI-Lo 2055-TBEB3 
Fuselage Frames 
Baseline: 2024-T4312 extr.f7175-T73 . 2024-T42f7075-T62 sht 
NewPr ucts:AI-LI2099-T83,N-li2099-T81 , 7055-T76511, 7055-T74511 
Fuselage Stringers 
Baseline: 7055-T76511HF, 6110-T6511 , 
2024-T3511 , 7075-T73511 
~ New Products:AI-Li2099-T83, 7055-T74511 
1.::1" . - "'" "'"""'" 
Lower Wing Stringers 
Current : 2026-T3511 , 2024-T3511 
New Products: AI-Li 2099-T81 , 
AI-Li 2099-T83 
Baseline: 
7175-T7351. 7050-T7452 
New Products: 
7085-T7452. AI-Lo-FG-1 , 
N -U-FG-2 
Products for Elevated Temps !Wheels/Pylon Areal 
Baseline: 2014A-T652 forgong, 2618A-T651 plate _ 
New Products: 2040-T62 forgong, 2099-T83 extrusions Green - Commercial 
Blue = Under Development 
Heinimann et a/, Alcoa, "Advanced Metallic and Hybrid Structural Solutions for Lig'ht-W4-~1Wl 
Aircraft Airworthiness & Sustainment Conference .... ~, .. .,..,. 
June 5-7, 2012 
Technical Approach 
NARI • 
• The principal objectives of Phase I : 
1. Fabricate a high specific strength aluminum-based metal 
matrix composite that can repair cracks using liquid-assisted 
self healing 
a. Targeting specific microstructural constituents based on 
thermodynamics and kinetics of the system. 
b. Testing various fabrication techniques for optimal performance 
2. Characterize the mechanical behavior of the novel a 
matrix constituent and composite before and afte 
a. Primarily tensile and fatigue testing 
3. Explore and optimize the reinforcement 
composites reinforced in a uniaxial and 
June 5-7, 2012 NASA Aeronautics Mission Directorate FYll Seedling 
Impact of Innovation 
NARI • 
• Improve damage tolerance and fatigue life of metals 
at critical structural locations 
• Alternative to conventional repair techniques of 
fatigued structures 
- Mechanically fastened, bonded, etc. 
• Integrated self-repairing approach would improve 
durability and sustainability of the aerospace 
material to ensure vehicle safety 
June 5-7, 2012 
Implications could revoluti 
industry and other NA-..-.-
Phase I Results 
NARI • 
• Fabricated, tested, and healed overload and fatigue cracks in 
proof-of-concept tin-bismuth (Sn-Bi) composite. 
• Proved self-healing in a cast binary AI-Si matrix alloy with pre-
determined eutectic phase and 2 val% Ni-Ti SMA wires. 
• Fatigue tested the self-healing binary AI-Si alloy to create a stress 
life (S-N) curve. 
• Fabricated two AI-Cu alloys with a pre-determined eutectic 
phase for self-healing: binary AI-Cu & ternary AI-Cu-Si. 
• Fabricated multi-ply test samples of AI-Cu-Si alloys b 
isostatically hot pressing thin slices of the matrix 
sandwiching SMA reinforcements at the inte"*oA 
June 5-7, 2012 
• 
Results: POC Material 
NARI • 
Fatigue tested proof-of-concept tin-bismuth {Sn-Bi) 
material to establish use of technology for cyclically 
loaded applications. 
June 5-7, 2012 
80 
70 
i 60 
! 
~so 
oJ , 
.~ 40 
c. 
~ 30 
Ill 
Ill 
Cll 
= 20 II\ 
10 
0 
1.000 
Proof of Concept (POC) Material Fatigue Testing 
• 
• • • 
•• 
• •• 
• Sn-Bi Matrix Only 
• SMA POC Composite E8 
L • SMA POC Composite E466 
10,000 100,000 
Number of Cycles to Failure, N1 
• 
Healing Fatigue Crack in POC 
NARI • 
Before: Post-Fat·gue Testing at KSC 
• • • o 1 ~ .. ~ ~~ ~ ,.. I ,.'; - ~ -~- -----
\ ,I 
After: Post-Hea at UF 
Proved healing of fatigu 
NASA Aeronautics Mission Directorate FY11 Seedling Dh~ • .-r ... l
Systematic Alloy Design 
NARI • 
• Thermodynamic 
approach used 
to design binary 
alloy. 
Castability 
Eutectic Temp 
Strength 
• Samples were 
cast in graphite 
mold 
0 
0 10 
Manuel et a/, "Design Methodology for Liquid-Assisted ~fJIR-.,_, 
41h International Conference on Self-Healing Materials, {:illfl~:l\1 
June 5-7, 2012 
Healing in AI-Si alloy 
NARI • 
• Binary AI-3Si cast at 
750°C; 120 r 
- 2 val% Ni/Ti SMA 
. 
w1res 
- Microstructural 
stabilization heat 
treatment at 592°C 
100 
"'80 D.. 
~ 
-~ 60 
cu 
... 
... 
VI 40 
20 
- Tensile tested, healing 0 
treatment, tensile 
tested again 
-composite D 
- composite D - Healed 
0 0.01 0.02 0.03 
Strain 
Proved self-healing with ---~-, ­
reco 
June S-7, 2012 NASA Aeronautics Mission Directorate FY11 Seedling 
Results: Healing in AI-Si 
NARI • 
• Microstructure showed uniform eutectic phase 
distribution and adequate wire bonding. 
- Eutectic phase distribution ideal for liquid-assisted healing 
Eutectic 
~Phase 
June 5-7, 2012 NASA Aeronautics Mission Directorate FYll Seedling ............... . 
Results: AI-Si Fatigue Behavior 
NARI • 
• Fatigue tested the 
self-healing binary AI-
Si alloy to create a S-N 
curve. 
- Significant variability in 
data due to porosity 
from fabrication 
technique 
- No effect of fatigue 
loading on SMA wires 
80 ---
~50 
G) 
~ 
.e 40 
Q. 
E < 30 -+ 
Binary AI-Si Composite Fatigue Testing 
Ill ~ .A AI-3Si Composite 
:: 20 -t- ,_ __ 
II) 
10 -
0 ...._ ~-----------
1,000 10,000 100,000 1,000,000 
Number of Cycles to Failure, Nt 
Cast binary alloy fatigue 
June 5-7, 2012 
Results: AI-Si Fatigue Behavior 
NARI • 
• Conducting fatigue crack growth tests on a middle tension M(T) and single 
edge notch tension ESE(T) specimens to grow and heal a small fatigue 
crack. 
Cracking occurs preferentially through eutectic along grain boundaries both pre 
and post healing. 
• Healing of micron-scale fatigue cracks, as well as macro-
scale machined notches achieved 
• Fatigue crack growth rate decreased after healing; 
dotted line represents healing treatment 
June 5-7, 2012 
0.3 
0.25 
g 0.2 
.1: 
tiO 
.i 0.15 
~ 
... 
.. 
0 0.1 
0.05 
0 
Pre-heal Post-heal 
I~ 
0 200 400 600 800 
Cycles (xlOOO) 
Results: AI-Cu alloys 
NARI • 
• Fabricated two AI-Cu alloys with a pre-determined 
eutectic phase for self-healing: 
Binary AI-Cu & ternary AI-Cu-Si. 
• AI-Cu alloys more brittle than the Al-
3wt%Si in tension 
140 • Little healing was evident in either r-
120 AI-9Cu-2Si Cu or AI-Cu-Si alloys. 
• It is theorized that the lack of 
- 100 
cu AI-10Cu 
AI-3Si did not allow for the 
martensite~ austenite r.ratomm:, a. :E 80 
-II) 
II) f 60 
... 
tn 
40 
20 
within the SMA wire, 
no closure force .. , .., .. , ...= 
matrix from 
• Without a callnllll 
0 ._ __ .___ _ ..___ _ _.__ _ __.___ _ _____, 
0 0.01 0.02 0.03 0.04 0.05 
Strain 
June 5-7, 2012 NASA Aeronautics Mission Directorate FY11 Seedling Phas;e;g~ 
Results: Diffusion Bonding Fabrication 
NARI • 
• Fabricated multi-ply test samples of AI-Cu-Si alloys by 
isostatically hot pressing thin slices of the matrix and 
sandwiching SMA reinforcements at the interface for 
diffusion bonding. 
- El iminates casting defects 
- Potential for improved strength and ductility 
- Composites with more complex wire geometries c 
fabricated 
June 5-7, 2012 
,..... 
"' c. ~ 
......-
"' 
"' ~ 
... 
V) 
Multi-ply Specimens (cont.) 
NARI • 
• Up to four plies with three reinforcement layers at 
the interfaces were successful I fabricated. 
140 
120 
Hot-Press: Y r= 1.67% 
100 
80 
60 
Cast: Y r= 2.32% 
40 
20 
0 -
0 0.002 0.004 0.006 0.000 0.01 0.012 
Strain 
Viable fabrication technique 
wase 
June 5-7, 2012 NASA Aeronautics Mission Directorate FY11 
Distribution/Dissemination 
NARI • 
• Submitted for NASA New Technology Report for future 
patent application. 
• International Conference of Self Healing Materials, Ghent, 
June 2013, Design Methodology for Liquid-Assisted Self-
Healing Metals. 
• Team will also continue to present results at relevant 
technical presentations {MS& T 2013, TMS 2014), 
least one peer-reviewed journal article, and b 
for inclusion in NASA technical publications 
Briefs. 
• The technology will be showcased at.,..,.,_ 
innovation day. 
June 5-7, 2012 NASA Aeronautics Mission Directorate FYll Seedling 
Next Steps 
NARI • 
• Phase II research will include: 
- Fu ll development and characterization of the fatigue life 
behavior of the AI-Cu-Si fabricated with unidirectional, 
multi-ply SMA reinforcements. 
- Modeling of the multi-ply specimens to determine 
optimal wire reinforcement {including long/short 
using SMA-specific finite element analysis (FEA). 
- Fabrication of multi-ply specimens with 
reinforcement and heat treatment to d 
multi-axis crack closure and healing 
fat igue cracks. 
June 5-7, 2012 NASA Aeronautics Mission Directorate FY11 Seedling 
Optional Funding 
NARI • 
• Design, model, and 
fabricate a small scale 
prototype based on 
aerostructural or non-
structural vehicle parts that 
have shown a history of 
fatigue cracking in the field. 
;!.62 
ASM Failure Analysis Center, Case Histories in Failure 
Analysis, 2024-T3 
Aluminum alloy 7075-
T73 landing-gear 
torque-arm assembly 
that was redesigned to 
eliminate fatigue 
fracture at a lubrication 
hole. 
d1om Secondary fracture 
( 0 ) Oti9lnal du";ln Improved deslon 
Oe1oii A 
Nose wheel fork 
failed when 
plane was i 
Team is requesting the additional 
repairing prototype an~ 
June 5-7, 2012 NASA Aeronautics Mission Directorate FYll Seedling 
Phase II Team 
NARI • 
• KSC- project management, fatigue testing, 
characterization 
• LaRC- specimen fabrication, healing 
• University of Florida- master alloy creation, 
healing of tested specimens 
• Northwestern University- FEA models 
(a) load 
1.. . (c) 
---_____,.--, 
June 5-7, 2012 


Thermo-mechanical Evaluation of Selfhealing Metallic Structures for Aerospace Vehicles Utilizing Shape Memory Alloys

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