Controlled shape-morphing metallic components for deployable structures

Ian D. McCue; Gianna M. Valentino; Douglas B. Trigg; Andrew M. Lennon; Chuck E. Hebert; Drew P. Seker; Salahudin M. Nimer; James P. Mastandrea; Morgana M. Trexler; Steven M. Storck

Materials & Design (Oct 2021)

Controlled shape-morphing metallic components for deployable structures

Ian D. McCue,
Gianna M. Valentino,
Douglas B. Trigg,
Andrew M. Lennon,
Chuck E. Hebert,
Drew P. Seker,
Salahudin M. Nimer,
James P. Mastandrea,
Morgana M. Trexler,
Steven M. Storck

Affiliations

Ian D. McCue: Research and Exploratory Development Department, Johns Hopkins University Applied Physics Laboratory, Laurel, MD 20723, USA
Gianna M. Valentino: Research and Exploratory Development Department, Johns Hopkins University Applied Physics Laboratory, Laurel, MD 20723, USA
Douglas B. Trigg: Research and Exploratory Development Department, Johns Hopkins University Applied Physics Laboratory, Laurel, MD 20723, USA
Andrew M. Lennon: Research and Exploratory Development Department, Johns Hopkins University Applied Physics Laboratory, Laurel, MD 20723, USA
Chuck E. Hebert: Force Projection Sector, Johns Hopkins University Applied Physics Laboratory, Laurel, MD 20723, USA
Drew P. Seker: Research and Exploratory Development Department, Johns Hopkins University Applied Physics Laboratory, Laurel, MD 20723, USA
Salahudin M. Nimer: Research and Exploratory Development Department, Johns Hopkins University Applied Physics Laboratory, Laurel, MD 20723, USA
James P. Mastandrea: Space Exploration Sector, Johns Hopkins University Applied Physics Laboratory, Laurel, MD 20723, USA
Morgana M. Trexler: Research and Exploratory Development Department, Johns Hopkins University Applied Physics Laboratory, Laurel, MD 20723, USA
Steven M. Storck: Research and Exploratory Development Department, Johns Hopkins University Applied Physics Laboratory, Laurel, MD 20723, USA; Corresponding author.

Journal volume & issue: Vol. 208
p. 109935

Abstract

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Transformational advances in additive manufacturing combined with the unique functional behavior of shape memory alloys (SMAs) has propelled the field of 4D printing “smart” materials. In this study, we leverage multiple processing pathways with additive manufacturing to design and fabricate SMA components capable of precise, self-guided shape change that could actuate large-scale (up to 25 × 25 × 33 cm3) structures under external thermal stimuli. The dual benefits of minor alloy doping (<2 at%) and laser processing parameters (laser hatch spacing) were identified to be the most effective method to engineer SMA joints and hinges with locally tailored transformation temperatures over a 90 °C range. Custom-designed plywood-style NiTi hinges with self-regulating features enabled tight bend radii and compact packing sizes. Implementation of these novel SMAs hinges with large deployment structures, mimicking solar panel arrays, demonstrated a 75–90% reduction in cross-sectional area compared to the fully deployed structure. The fundamental understanding and demonstration of tailored and controlled complex shape-morphing kinematics, without the use of specialized and heavy external motors, lays the groundwork for future SMA-enabled deployable structures in remote environments.

Published in Materials & Design

ISSN: 0264-1275 (Print); 1873-4197 (Online)
Publisher: Elsevier
Country of publisher: United Kingdom
LCC subjects: Technology: Electrical engineering. Electronics. Nuclear engineering: Materials of engineering and construction. Mechanics of materials
Website: https://www.journals.elsevier.com/materials-and-design

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